Page:1 of 12 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

Scaling Factor 

Relative to Base 

Jetta CT

Value 

05 LAUNCH CLUTCHES: 

1 01 Torque Converter Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description Lauch Clutch Data Acquied from Jetta 6-

Speed Wet DCT Analyis 

 Conversion from DCT Application to 

Net Launch Clutch for IMGA

Component/ 

Assembly 

Cost Impact to 

OEM

SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NEW TECHNOLOGY PACKAG

6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW 

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen and Mid Size Passenger Car, 5 Passengers

Study Case#: N0902 & B0802 (N=New, B=Base, ) 08/09=Technology Package, 02=Vehicle Class

2 02 Clutch Assembly C1/C2 $ 24.21 $ 11.41 $ 39.58 $ 75.19 $ 0.43 $ 5.50 $ 5.19 $ 0.91 $ 12.03 $ 0.35 $ 87.58 Use 50% of cost since only single clutch is 

required 0.50 $ 31.39

0.16

3 03 Fly Wheels/Flex Plates/Starter Rings $ 24.33 $ 11.40 $ 13.85 $ 49.58 $ 0.52 $ 2.09 $ 1.93 $ 0.32 $ 4.86 $ 0.24 $ 54.67 Full Value Used 1.00 $ 63.10

0.10

4 04 TBD $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 15 Snap Rings and Retainers $ 1.76 $ 0.97 $ 2.40 $ 5.13 $ 0.03 $ 0.33 $ 0.31 $ 0.05 $ 0.71 $ 0.06 $ 5.91 Use 50% of cost since onlu single clutch is 

required 0.50 $ 2.28

0.14

20 20 Springs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

70 70 Pipes, Hoses, Ducting Pipes, Hoses, Ducting $ $ - $ $ - $ $ - $ $ - $ - $ - $ - $ - $ $ - $ $ - $ $ -

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:2 of 12 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

Scaling Factor 

Relative to Base 

Jetta CT

Value 

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description Lauch Clutch Data Acquied from Jetta 6-

Speed Wet DCT Analyis 

 Conversion from DCT Application to 

Net Launch Clutch for IMGA

Component/ 

Assembly 

Cost Impact to 

OEM

SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NEW TECHNOLOGY PACKAG

6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW 

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen and Mid Size Passenger Car, 5 Passengers

Study Case#: N0902 & B0802 (N=New, B=Base, ) 08/09=Technology Package, 02=Vehicle Class

75 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

80 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

85 85 Sealing Elements $ 0.03 $ 0.19 $ 0.44 $ 0.67 $ 0.00 $ 0.04 $ 0.04 $ 0.01 $ 0.09 $ 0.05 $ 0.81 Use 50% of cost since onlu single clutch is 

required 0.50 $ 0.04

0.14

90 90 Bearing Elements $ 0.07 $ 0.11 $ 0.25 $ 0.43 $ 0.00 $ 0.03 $ 0.02 $ 0.00 $ 0.06 $ 0.02 $ 0.51 Use 50% of cost since onlu single clutch is 

required 0.50 $ 0.09

0.13

99 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

00 00 Transmission Assembly of Launch Clutches $ 1.12 $ 4.44 $ 3.46 $ 9.03 $ - $ - $ - $ - $ - $ - $ 9.03 Use 50% of cost since onlu single clutch is 

required 0.50 $ 1.45

0.00

$ 51.52 $ 28.52 $ 59.99 $ 140.02 $ 0.99 $ 7.99 $ 7.49 $ 1.30 $ 17.76 $ 0.72 $ 158.50 $ - $ 98.35

Baseline

0.553676001 1.16443926 0.126820621

SUBSYSTEM ROLL-UP

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:3 of 12 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

Scaling Factor 

Relative to Base 

Jetta CT

Value 

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description Lauch Clutch Data Acquied from Jetta 6-

Speed Wet DCT Analyis 

 Conversion from DCT Application to 

Net Launch Clutch for IMGA

Component/ 

Assembly 

Cost Impact to 

OEM

SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NEW TECHNOLOGY PACKAG

6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW 

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen and Mid Size Passenger Car, 5 Passengers

Study Case#: N0902 & B0802 (N=New, B=Base, ) 08/09=Technology Package, 02=Vehicle Class

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:4 of 12 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

Scaling Factor 

Relative to Base 

Jetta CT

Value 

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description Lauch Clutch Data Acquied from Jetta 6-

Speed Wet DCT Analyis 

 Conversion from DCT Application to 

Net Launch Clutch for IMGA

Component/ 

Assembly 

Cost Impact to 

OEM

SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NEW TECHNOLOGY PACKAG

6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW 

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen and Mid Size Passenger Car, 5 Passengers

Study Case#: N0902 & B0802 (N=New, B=Base, ) 08/09=Technology Package, 02=Vehicle Class

Material Labor Burden End Item 

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

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

Item

Subsystem

BASE 

TECHNO

LOGY 

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

Sub-Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:5 of 12 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

Scaling Factor 

Relative to Base 

Jetta CT

Value 

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description Lauch Clutch Data Acquied from Jetta 6-

Speed Wet DCT Analyis 

 Conversion from DCT Application to 

Net Launch Clutch for IMGA

Component/ 

Assembly 

Cost Impact to 

OEM

SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NEW TECHNOLOGY PACKAG

6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW 

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen and Mid Size Passenger Car, 5 Passengers

Study Case#: N0902 & B0802 (N=New, B=Base, ) 08/09=Technology Package, 02=Vehicle Class

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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!

Material Labor Burden End Item 

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

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 02 $ 24.21 $ 11.41 $ 39.58 $ 75.19 $ 0.43 $ 5.50 $ 5.19 $ 0.91 $ 12.03 $ 0.35 $ 87.58

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem

Manufacturing Net 

Component/ 

Assembly 

Cost Impact to 

OEM

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

C1 03 $ 24.33 $ 11.40 $ 13.85 $ 49.58 $ 0.52 $ 2.09 $ 1.93 $ 0.32 $ 4.86 $ 0.24 $ 54.67

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:6 of 12 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

Scaling Factor 

Relative to Base 

Jetta CT

Value 

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description Lauch Clutch Data Acquied from Jetta 6-

Speed Wet DCT Analyis 

 Conversion from DCT Application to 

Net Launch Clutch for IMGA

Component/ 

Assembly 

Cost Impact to 

OEM

SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NEW TECHNOLOGY PACKAG

6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW 

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen and Mid Size Passenger Car, 5 Passengers

Study Case#: N0902 & B0802 (N=New, B=Base, ) 08/09=Technology Package, 02=Vehicle Class

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

E1 65 $ 1.76 $ 0.97 $ 2.40 $ 5.13 $ 0.03 $ 0.33 $ 0.31 $ 0.05 $ 0.71 $ 0.06 $ 5.91

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

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

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

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

J1 80 $ 0.03 $ 0.19 $ 0.44 $ 0.67 $ 0.00 $ 0.04 $ 0.04 $ 0.01 $ 0.09 $ 0.05 $ 0.81

K1 85 $ 0.07 $ 0.11 $ 0.25 $ 0.43 $ 0.00 $ 0.03 $ 0.02 $ 0.00 $ 0.06 $ 0.02 $ 0.51

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

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

M1 99 $ 1.12 $ 4.44 $ 3.46 $ 9.03 $ - $ - $ - $ - $ - $ - $ 9.03

N1 00 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

SU

BS

YS

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:7 of 12 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

05 LAUNCH CLUTCHES: 

1 01

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

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 

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 

Calculate material (M) usage change based on Engine Torq. 

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Scaling Parameter(s) Description

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

NEW TECHNOLOGY PACKAGE COST INFORMATION

eed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

2 02

3 03

4 04

15 15

20 20

70 70

Calculate material (M) usage change based on Engine Torq. 

(package volume based). Calculate labor (L), mfging overhead 

(MOH), and Mark-up (MU) price changes using L/M=0.553 and 

MOH/M=1.164 and 'MU/TMC=0.127 ratios. 

0.73 $ 27.09 0.77 $ 28.53 0.90 $ 33.39 0.85 $ 31.55 0.86 $ 31.69 0.99 $ 36.63

Calculate material (M) usage change based on Engine Torque 

(package volume based). Calculate labor (L), mfging overhead 

(MOH), and Mark-up (MU) price changes using L/M=0.553 and 

MOH/M=1.164 and 'MU/TMC=0.127 ratios developed for baseline 

castings.

0.73 $ 54.45 0.77 $ 57.36 0.90 $ 67.11 0.85 $ 63.42 0.86 $ 63.71 0.99 $ 73.62

Calculate material (M) usage change based on Engine Torque 

(package volume based). Calculate labor (L), mfging overhead 

(MOH), and Mark-up (MU) price changes using L/M=0.553 and 

MOH/M=1.164 and 'MU/TMC=0.127 ratios developed for baseline 

castings.

0.73 $ 1.97 0.77 $ 2.07 0.90 $ 2.43 0.85 $ 2.29 0.86 $ 2.30 0.99 $ 2.66

70 70

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:8 of 12 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

75 75

80 80

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 

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 

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Scaling Parameter(s) Description

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

NEW TECHNOLOGY PACKAGE COST INFORMATION

eed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Calculate material (M) usage change based on Engine Torque 

85 85

90 90

99 99

00 00

Calculate material (M) usage change based on Engine Torque 

(package volume based). Calculate labor (L), mfging overhead 

(MOH), and Mark-up (MU) price changes using L/M=0.553 and 

MOH/M=1.164 and 'MU/TMC=0.127 ratios developed for baseline 

castings.

0.73 $ 0.03 0.77 $ 0.03 0.90 $ 0.04 0.85 $ 0.04 0.86 $ 0.04 0.99 $ 0.04

Calculate material (M) usage change based on Engine Torque 

(package volume based). Calculate labor (L), mfging overhead 

(MOH), and Mark-up (MU) price changes using L/M=0.553 and 

MOH/M=1.164 and 'MU/TMC=0.127 ratios developed for baseline 

castings.

0.73 $ 0.08 0.77 $ 0.08 0.90 $ 0.10 0.85 $ 0.09 0.86 $ 0.09 0.99 $ 0.11

Calculate material (M) usage change based on Engine Torque 

(package volume based). Calculate labor (L), mfging overhead 

(MOH), and Mark-up (MU) price changes using L/M=0.553 and 

MOH/M=1.164 and 'MU/TMC=0.127 ratios developed for baseline 

castings.

0.73 $ 1.25 0.77 $ 1.32 0.90 $ 1.54 0.85 $ 1.46 0.86 $ 1.47 0.99 $ 1.69

$ 84.87 $ 89.40 $ 104.61 $ 98.86 $ 99.30 $ 114.75

1 2 3 4 5 6

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:9 of 12 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

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 

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 

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Scaling Parameter(s) Description

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

NEW TECHNOLOGY PACKAGE COST INFORMATION

eed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:10 of 12 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

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 

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 

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Scaling Parameter(s) Description

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

NEW TECHNOLOGY PACKAGE COST INFORMATION

eed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

Item

Subsystem

BASE 

TECHNO

LOGY 

Sub-Subsystem

F1 66

2

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:11 of 12 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

G1 67

2

H1 70

2

I1 75

2

J1 80

2

K1 85

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 

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 

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Scaling Parameter(s) Description

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

NEW TECHNOLOGY PACKAGE COST INFORMATION

eed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

K1 85

2

L1 90

2

M1 99

2

N1 00

2

SU

BS

YS

05 Cylinder Blocks

A1 01

B1 02

Item

Subsystem

Sub-Subsystem

TECHNO

LOGY 

PACKAG

C1 03

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:12 of 12 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

D1 04

E1 65

F1 66

G1 67

H1 70

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 

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 

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Scaling Parameter(s) Description

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

NEW TECHNOLOGY PACKAGE COST INFORMATION

eed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

N1 00

SU

BS

YS

09000064810ec171.xls

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

Author: D. McDowell

(248)373-6000
Page:1 of 2 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 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

020500 Launch Clutch Subsystem: Integrated Motor-Generator Assembly (IMGA) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

1 01 Torque Converter Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

2 02 Clutch Assembly C1/C2 $ 24.21 $ 11.41 $ 39.58 $ 75.19 $ 0.43 $ 5.50 $ 5.19 $ 0.91 $ 12.03 $ 0.35 $ 87.58 $ - $ - $ -

A D6 C1/C2 Asm 02 05 02 - N0902 - 01 1 Full pia to 020500-N0902-00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A1 D6 C1/C2 Welded Hub Asm; C1/C2 Asm 02 05 02 - N0902 - 02 1 Full $ 2.85 $ 2.14 $ 5.23 $ 10.22 $ 0.10 $ 1.24 $ 1.14 $ 0.19 $ 2.66 $ 0.02 $ 12.90 $ - $ - $ -

A2 D6 Outer Clutch Hub; Welded Hub Asm 02 05 02 - N0902 - 03 1 Full pia to 020502-N0902-02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A3 D6 Pusher Plate; Welded Hub Asm 02 05 02 - N0902 - 04 1 Full pia to 020502-N0902-02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A4 D6 Inner Clutch Hub; Welded Hub Asm 02 05 02 - N0902 - 05 1 Full pia to 020502-N0902-02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

S

Assembly) ubsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Subassembly

Component

Sub-Subsystem

Investment

(X1000)

Tooling 

(x1000)

Markup

Assembly

Name/Description

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/

Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

 VW 6 Speed Direct Shift Gearbox (dual clutch)

(Max Torque Capacity 207 lb*ft)

Item

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen Passenger Car, 5 Passengers

Study Case#: N0902 (N=New, 09=Technology Package, 02=Vehicle Class )

A5 D6 Inner Clutch Hub Casting Upper; Welded 

Hub Asm 02 05 02 - N0902 - 06 1 Full $ 0.96 $ 0.81 $ 2.26 $ 4.02 $ 0.03 $ 0.28 $ 0.32 $ 0.08 $ 0.71 $ 0.01 $ 4.74 $ - $ - $ -

A6 D6 Inner Clutch Hub Casting Lower; Welded 

Hub Asm 02 05 02 - N0902 - 07 1 Full $ 0.40 $ 0.80 $ 2.24 $ 3.44 $ 0.02 $ 0.24 $ 0.28 $ 0.07 $ 0.61 $ 0.01 $ 4.05 $ - $ - $ -

A7 D6 Piston Return Spring Seat w/seal; C1/C2 

Asm 02 05 02 - N0902 - 08 1 Full $ 0.35 $ 0.28 $ 1.22 $ 1.85 $ 0.01 $ 0.12 $ 0.11 $ 0.02 $ 0.26 $ 0.01 $ 2.12 $ - $ - $ -

A8 D6 Piston Return Spring Asm; C1/C2 Asm 02 05 02 - N0902 - 09 1 Full $ 0.79 $ 0.44 $ 0.81 $ 2.04 $ 0.01 $ 0.13 $ 0.12 $ 0.02 $ 0.29 $ 0.09 $ 2.42 $ - $ - $ -

A9 D6 Piston w/seal; C1/C2 Asm 02 05 02 - N0902 - 10 1 Full $ 0.22 $ 0.22 $ 0.96 $ 1.40 $ 0.01 $ 0.09 $ 0.08 $ 0.01 $ 0.20 $ 0.01 $ 1.61 $ - $ - $ -

A10 D6 Inner Clutch Thrust Surface; C1/C2 Asm 02 05 02 - N0902 - 11 1 Full $ 0.03 $ 0.03 $ 0.07 $ 0.12 $ 0.00 $ 0.01 $ 0.01 $ 0.00 $ 0.02 $ 0.01 $ 0.15 $ - $ - $ -

A11 D6 Outer Clutch Pack Asm; C1/C2 Asm 02 05 02 - N0902 - 12 1 Full $ 7.54 $ 1.32 $ 6.30 $ 15.17 $ 0.08 $ 0.99 $ 0.91 $ 0.15 $ 2.12 $ 0.03 $ 17.32 $ - $ - $ -

A12 D6 Outer Clutch Ring; Outer Clutch Pack 02 05 02 - N0902 - 13 5 Full pia to 020502-N0902-12 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A13 D6 Outer Clutch Disk; Outer Clutch Pack 02 05 02 - N0902 - 14 4 Full pia to 020502-N0902-12 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A14 D6 Outer Reaction Plate; Outer Clutch Pack 02 05 02 - N0902 - 15 1 Full pia to 020502-N0902-12 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A15 D6 Inner Clutch Pack Asm; C1/C2 Asm 02 05 02 - N0902 - 16 1 Full $ 4.33 $ 1.60 $ 8.68 $ 14.60 $ 0.07 $ 0.95 $ 0.88 $ 0.15 $ 2.04 $ 0.03 $ 16.67 $ - $ - $ -

A16 D6 Inner Clutch Ring; Inner Clutch Pack 02 05 02 - N0902 - 17 6 Full pia to 020502-N0902-16 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A17 D6 Inner Clutch Disk; Inner Clutch Pack 02 05 02 - N0902 - 18 5 Full pia to 020502-N0902-16 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A18 D6 Inner Reaction Plate; Inner Clutch Pack 02 05 02 - N0902 - 19 1 Full pia to 020502-N0902-16 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A19 D6 Center Hub Asm; C1/C2 Asm 02 05 02 - N0902 - 20 1 Full $ 0.45 $ 1.02 $ 3.33 $ 4.80 $ 0.02 $ 0.31 $ 0.29 $ 0.05 $ 0.67 $ 0.04 $ 5.51 $ - $ - $ -

A20 D6 Center Hub Forging; Center Hub Asm 02 05 02 - N0902 - 21 1 Full pia to 020502-N0902-20 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A21 D6 Center Hub Stamping; Center Hub Asm 02 05 02 - N0902 - 22 1 Full pia to 020502-N0902-20 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B D6 C1 Hub Asm; C1/C2 Asm 02 05 02 - N0902 - 23 1 Full $ 2.03 $ 1.61 $ 5.18 $ 8.82 $ 0.04 $ 0.57 $ 0.53 $ 0.09 $ 1.24 $ 0.04 $ 10.10 $ - $ - $ -

B1 D6 Outer Hub; C1 Hub Asm 02 05 02 - N0902 - 24 1 Full pia to 020502-N0902-23 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B2 D6 Center Bearing; C1 Hub Asm 02 05 02 - N0902 - 25 1 Full pia to 020502-N0902-23 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C D6 Outer Shell Asm; C1/C2 Asm 02 05 02 - N0902 - 26 1 Full $ 2.05 $ 0.84 $ 2.46 $ 5.34 $ 0.03 $ 0.35 $ 0.32 $ 0.05 $ 0.75 $ 0.04 $ 6.13 $ - $ - $ -

C1 D6 Outer Shell; Outer Shell Asm 02 05 02 - N0902 - 27 1 Full pia to 020502-N0902-26 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C2 D6 Cover Center; Outer Shell Asm 02 05 02 - N0902 - 28 1 Full pia to 020502-N0902-26 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D D6 C1 Cover w/overmold; C1/C2 Asm 02 05 02 - N0902 - 29 1 Full $ 2.22 $ 0.29 $ 0.85 $ 3.36 $ 0.02 $ 0.22 $ 0.20 $ 0.03 $ 0.47 $ 0.04 $ 3.86 $ - $ - $ -

3 03 Fly Wheels/Flex Plates/Starter Rings $ 24.33 $ 11.40 $ 13.85 $ 49.58 $ 0.52 $ 2.09 $ 1.93 $ 0.32 $ 4.86 $ 0.24 $ 54.67 $ - $ - $ -

A Dual Mass Fly Wheel Asm X 02 05 03 - N0902 - 01 1 Full $ 6.64 $ 8.06 $ 2.75 $ 17.45 $ - $ - $ - $ - $ - $ - $ 17.45 $ - $ - $ -

A1 Pressure Plate; DMFW Asm X 02 05 03 - N0902 - 02 1 Full $ 3.05 $ 1.31 $ 3.68 $ 8.03 $ 0.40 $ 0.52 $ 0.48 $ 0.08 $ 1.49 $ 0.06 $ 9.57 $ - $ - $ -

B Fly Weel Asm; DMFW Asm X 02 05 03 - N0902 - 03 1 Full pia to 020503-N0902-01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 Fly Weel (stamped); Fly Wheel Asm X 02 05 03 - N0902 - 04 1 Full $ 8.84 $ 0.44 $ 1.79 $ 11.07 $ 0.06 $ 0.72 $ 0.66 $ 0.11 $ 1.55 $ 0.09 $ 12.71 $ - $ - $ -

B2 Starter Ring Gear; Fly Wheel Asm X 02 05 03 - N0902 - 05 1 Full $ 1.41 $ $ 1.18 $ 3.94 $ $ 6.54 $ 0.03 $ 0.42 $ 0.39 $ 0.07 $ $ 0.92 $ $ 0.09 $ $ 7.54 $ - $ - $ -

B3 Outer Cover Pan; Fly Wheel Asm X 02 05 03 - N0902 - 06 1 Full $ 4.40 $ 0.40 $ 1.69 $ 6.49 $ 0.03 $ 0.42 $ 0.39 $ 0.06 $ 0.91 $ 0.00 $ 7.40 $ - $ - $ -

09000064810ec171.xls

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

Author: D. McDowelll

(248)373-6000
Page:2 of 2 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

Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

S

Assembly) ubsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Subassembly

Component

Sub-Subsystem

Investment

(X1000)

Tooling 

(x1000)

Markup

Assembly

Name/Description

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/

Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

 VW 6 Speed Direct Shift Gearbox (dual clutch)

(Max Torque Capacity 207 lb*ft)

Item

Technology Level: Toyota 6 Speed Automatic Transmission versus VW 6 Speed Direct Shift Gearbox

Vehicle Class: SportWagen Passenger Car, 5 Passengers

Study Case#: N0902 (N=New, 09=Technology Package, 02=Vehicle Class )

4 X 04 TBD $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 05 20 - N0902 - ** $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

15 X 15 Snap Rings and Retainers $ 1.76 $ 0.97 $ 2.40 $ 5.13 $ 0.03 $ 0.33 $ 0.31 $ 0.05 $ 0.71 $ 0.06 $ 5.91 $ - $ - $ -

A Thrust Ring Retainer; DMFW Asm X 02 05 15 - N0902 - 01 1 Full $ 0.04 $ 0.03 $ 0.06 $ 0.13 $ 0.00 $ 0.01 $ 0.01 $ - $ 0.01 $ 0.00 $ 0.15 $ - $ - $ -

B Spring Retainer; Fly Wheel Asm X 02 05 15 - N0902 - 02 1 Full $ 0.12 $ 0.23 $ 0.52 $ 0.87 $ 0.00 $ 0.06 $ 0.05 $ 0.01 $ 0.12 $ 0.01 $ 1.00 $ - $ - $ -

C Spring Washer; Fly Wheel Asm X 02 05 15 - N0902 - 03 1 Full $ 0.24 $ 0.22 $ 0.50 $ 0.97 $ 0.00 $ 0.06 $ 0.06 $ 0.01 $ 0.14 $ 0.00 $ 1.10 $ - $ - $ -

D Spring Stop; Fly Wheel Asm X 02 05 15 - N0902 - 04 1 Full $ 0.24 $ 0.24 $ 0.55 $ 1.03 $ 0.01 $ 0.07 $ 0.06 $ 0.01 $ 0.14 $ 0.02 $ 1.18 $ - $ - $ -

E Spring Stop Cover; Fly Wheel Asm X 02 05 15 - N0902 - 05 1 Full $ 0.09 $ 0.03 $ 0.08 $ 0.20 $ 0.00 $ 0.01 $ 0.01 $ 0.00 $ 0.03 $ 0.00 $ 0.23 $ - $ - $ -

F Steel Ring; Fly Wheel Asm X 02 05 15 - N0902 - 06 1 Full $ 0.46 $ 0.03 $ 0.08 $ 0.57 $ 0.00 $ 0.04 $ 0.03 $ 0.01 $ 0.08 $ 0.02 $ 0.66 $ - $ - $ -

G Ring nRetainer; Fly Wheel Asm X 02 05 15 - N0902 - 07 1 Full $ 0.56 $ 0.20 $ 0.60 $ 1.37 $ 0.01 $ 0.09 $ 0.08 $ 0.01 $ 0.19 $ 0.02 $ 1.58 $ - $ - $ -

20 X 20 Springs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 1.00 $ - $ - $ -

A Spring Asm; DMFW Asm X 02 05 20 - N0902 - 01 1 Full pia to 020503-N0902-01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A1 Large Spring; Spring Asm X 02 05 20 - N0902 - 02 2 Full pia to 020520-N0902-01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A2 Small Spring; Spring Asm Small Spring; Spring Asm X 02 05 20 - N0902 - 03 4 Full pia to 020520-N0902-01 pia to 020520-N0902-01 $ - $ $ - $ - $ $ - $ - $ - $ - $ - $ $ - $ $ 1.00 $ $ 1.00 $ $ - $ $ - $ $ -

B

D6 Outer Clutch Hub Return Spring; Welded 

Hud Asm X 02 05 20 - N0902 - 04 2 Full pia to 020502-N0902-02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C D6 Spring; C1/C2 Spring Plate Asm X 02 05 20 - N0902 - 05 22 Full pia to 020502-N0902-09 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 1.00 $ 1.00 $ - $ - $ -

70 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

75 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

80 X 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A Rivet; DMFW Asm X 02 05 80 - N0902 - 01 8 Full pia to 020502-N0902-01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B Rivet Small; Fly Wheel Asm X 02 05 80 - N0902 - 02 3 Full pia to 020502-N0902-02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

85 85 Sealing Elements $ 0.03 $ 0.19 $ 0.44 $ 0.67 $ 0.00 $ 0.04 $ 0.04 $ 0.01 $ 0.09 $ 0.05 $ 0.81 $ - $ - $ -

A D6 Center Seal; C1/C2 Asm 02 05 85 - N0902 - 01 1 Full pia to 020502-N0902-29 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B Sealing Ring; C1/C2 Asm 02 05 85 - N0902 - 02 4 Full $ 0.03 $ 0.19 $ 0.44 $ 0.67 $ 0.00 $ 0.04 $ 0.04 $ 0.01 $ 0.09 $ 0.05 $ 0.81 $ - $ - $ -

90 X 90 Bearing Elements $ 0.07 $ 0.11 $ 0.25 $ 0.43 $ 0.00 $ 0.03 $ 0.02 $ 0.00 $ 0.06 $ 0.02 $ 0.51 $ - $ - $ -

A Thrust Bearing; DMFW Asm X 02 05 90 - N0902 - 01 1 Full $ 0.01 $ 0.02 $ 0.04 $ 0.07 $ 0.00 $ 0.00 $ 0.00 $ - $ 0.01 $ 0.00 $ 0.08 $ - $ - $ -

B Plastic Ring Bearing; Fly Wheel Asm X 02 05 90 - N0902 - 02 1 Full $ 0.06 $ 0.09 $ 0.21 $ 0.36 $ 0.00 $ 0.02 $ 0.02 $ 0.00 $ 0.05 $ 0.02 $ 0.43 $ - $ - $ -

C D6 Bearing Thrust; C1 Hub Asm 02 05 90 - N0902 - 03 1 Full pia to 020502-N0902-23 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D D6 Bearing - clutch set; Outer Shell Asm 02 05 90 - N0902 - 04 1 Full pia to 020502-N0902-26 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

E D6 Center Bearing Sleeve; C1/C2 Asm 02 05 90 - N0902 - 05 1 Full $ 0.33 $ 0.44 $ 1.15 $ 1.91 $ 0.01 $ 0.13 $ 0.15 $ 0.04 $ 0.34 $ 0.02 $ 2.27 $ - $ - $ -

99 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A 02 05 99 - N0902 - 01 51 Full pia to clutch disks

qty in square inches used $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B 02 05 99 - N0902 - 02 18 Full pia to clutch disks

qty in square inches used $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

00 00 Transmission Assembly of Launch Clutches $ 1.12 $ 4.44 $ 3.46 $ 9.03 $ - $ - $ - $ - $ - $ - $ 9.03 $ - $ - $ -

A

OEM Assembly costs associated with launch 

controls 02 05 00 - N0902 - 00 1 Full $ 1.12 $ 4.44 $ 3.46 $ 9.03 $ - $ - $ - $ - $ - $ - $ 9.03 $ - $ - $ -

$ 51.52 $ 28.52 $ 59.99 $ 140.02 $ 0.99 $ 7.99 $ 7.49 $ 1.30 $ 17.76 $ 0.72 $ 158.50 $ - $ - $ -

D6 Friction paper; Clutch Disks

D6 Phenolic Adhesive; Clutch Disks

$ 51.52 $ 28.52 $ 59.99 $ 140.02 $ 0.99 $ 7.99 $ 7.49 $ 1.30 $ 17.76 $ 0.72 $ 158.50 $ - $ - $ -

NA Complete Subsystem Quote 

(Yes/No)

09000064810ec171.xls

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

Author: D. McDowelll

(248)373-6000
Powertrain Description: 2005-2009 VW Jetta Sportswagen, 6 Speed DSG Transmission

Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Study Case#: N0902 (N = New, 08 = Technology Package, 02 = Vehicle Class )

ITEM

ASY LVL

QTY/ 

P.T.

Label #

Qty

02 TRANSMISSION SYSTEM

X 01 EXTERNAL COMPONENTS: Consists of installation of oil coolers, lift eyes, vent caps.

02 01 00 - N0902 - 00

X 01

X 02 01 01 - N0902 - **

X 02

X 02 01 02 - N0902 - **

X 03

X 02 01 03 - N0902 - **

X 04

X 02 01 04 - N0902 - **

X 05

X 02 01 05 - N0902 - **

X 70

X 02 01 70 - N0902 - **

X 75

X 02 01 75 - N0902 - **

X 80

X 02 01 80 - N0902 - **

X 85

X 02 01 85 - N0902 - **

X 90

Pipes, Hoses, Ducting

Brackets

Indicates cost analysis potentially required, additional details 

required.

Indicates common item/cost factor found in both baseline and 

new technology package, no cost analysis required.

Same as above, however with potential MCR or Technology 

Advance Considerations

QTY/P.T.

Royalty

Material/Finish(s)

Performance

COMPONENT

Default, indicates cost study required for identified item.

Part Existenc

S

e

UBSYSTEM

SUB-SUBSYSTEM

ASSEMBLY

SUBASSEMBLY

Weight/ Size

Function

NAME/DECRIPTION

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

PART NUMBER

Boltings

Sealing Elements

Bearing Elements

GENERAL PART 

INFORMATION

X

?

X

X 90

X 02 01 90 - N0902 - **

X 99

X 02 01 99 - N0902 - **

02 CASE(S): Includes pressed in components (i.e., bearing races), plugs, and associated hardware.

02 02 00 - N0902 - 00

01

A 02 02 01 - N0902 - 01 1

B 02 02 01 - N0902 - 02 1

02

A 02 02 02 - N0902 - 01 1

B 02 02 02 - N0902 - 02 1

03

02 02 03 - N0902 - **

04

A 02 02 04 - N0902 - 01 2

B 02 02 04 - N0902 - 02 6

C 02 02 04 - N0902 - 03 2

D 02 02 04 - N0902 - 04 6

E 02 02 04 - N0902 - 05 4

05

02 02 05 - N0902 - **

10

02 02 10 - N0902 - **

70

02 02 70 - N0902 - **

75

02 02 75 - N0902 - **

80

A 02 02 80 - N0902 - 01 18

B 02 02 80 - N0902 - 02 3

85

Plugs 

Piston Fork Travel Small; Case Front & Rear

D6 Fork Piston Bore; Case Front &Rear

D6 Fork Piston Bore Small; Case Front & Rear

Case Assembly Front

Case Assembly Rear

D6 Case Asm - Front

D6 Case; Front Asm

Miscellaneous

Bearing Elements

D6 Case Asm - Rear 

Covers

Actuators

D6 Detent Spring - Shift Fork; Rear Asm

D6 Case; Rear Asm

Piston Fork Travel; Case Front & Rear

Pipes, Hoses, Ducting

Brackets

Boltings 

Sealing Elements

D6 Bolt - Case Front, Large

D6 Bolt - Case Front, Small
A 02 02 85 - N0902 - 01 1

B 02 02 85 - N0902 - 02 1

C 02 02 85 - N0902 - 03 1

90

A 02 02 90 - N0902 - 01 1

B 02 02 90 - N0902 - 02 1

C 02 02 90 - N0902 - 03 1

D 02 02 90 - N0902 - 04 1

E 02 02 90 - N0902 - 05 1

F 02 02 90 - N0902 - 06 1

G 02 02 90 - N0902 - 07 1

H 02 02 90 - N0902 - 08 1

I 02 02 90 - N0902 - 09 1

J 02 02 90 - N0902 - 10 1

K 02 02 90 - N0902 - 11 1

L 02 02 90 - N0902 - 12 1

M 02 02 90 - N0902 - 13 1

99

A 02 02 99 - N0902 - 01 2

B 02 02 99 - N0902 - 02 1

03 GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential and all associated gears and bearings on the shaft. 

02 03 00 - N0902 - 00

01

A 02 03 01 - N0902 - 01 1

B 02 03 01 - N0902 - 02 1

 B1 02 03 01 - N0902 - 03 1

B2 02 03 01 - N0902 - 04 1

B3 02 03 01 - N0902 - 05 1

B4 02 03 01 - N0902 - 06 1

B5 02 03 01 - N0902 - 07 1

02

A 02 03 02 - N0902 - 01 1

B 02 03 02 - N0902 - 02 1

C 02 03 02 - N0902 - 03 1

03

A 02 03 03 - N0902 - 01 1

A1 02 03 03 - N0902 - 02 1

A2 02 03 03 - N0902 - 03 1

A3 02 03 03 - N0902 - 04 1

A4 02 03 03 - N0902 - 05 1

A5 02 03 03 - N0902 - 06 1

D6 3rd Gear Asm; Output Shaft 1/3/4/2 Asm

D6 Thrust Bearing Rev Shaft Lrg; Front Asm

Input Shaft Inner

Vent Cap; Rear Asm

D6 Input Shaft Outer Sensor; Input Shaft Outer Asm

Output Shaft, 1 thru 4

D6 Bearing Input Shaft; Rear Asm

D6 Bearing Rev Transfer Shaft; Rear Asm

Seal Differntial Output; Rear Asm

Bearing Elements

D6 Seal - Case to Case Oil Passage; Front Asm

D6 Shim Differential Bearing; Rear Asm

D6 Input Shaft Asm

D6 Bearing Race Differential; Rear Asm

D6 Race 56R shaft; Front Asm

D6 Dowel Case to Case; Front Asm

D6 Seal Axle Shaft; Front Asm

D6 Bearing Race 1-2-3-4 Output shaft; Rear Asm

D6 Shim 5-6-R Shaft Bearing; Rear Asm

D6 Bearing Race 5-6-R Output shaft; Rear Asm

D6 Input Shaft Inner; Input Inner Shaft Sub-Asm

D6 Input Shaft Inner Lg Gear; Input Shaft Inner Sub-Asm

D6 Input Shaft Inner Sensor; Input Shaft Inner Sub-Asm

D6 Input Shaft Inner Medium Gear; Input Shaft Inner 

Sub-Asm

D6 Input Shaft Inner Sub-Asm

D6 Needle Bearing Rev Shaft; Front Asm

D6 Bearing Input Shaft clutch side; Front Asm

D6 Snap-ring input shaft bearing; Front Asm

D6 Race 1234 shaft; Front Asm

Miscellaneous

D6 Input Shaft Outer; Input Shaft Outer Asm

D6 Shaft 1/3/4/2; Output Shaft 1/3/4/2 Asm

D6 3rd Gear; 3rd Gear Asm

D6 Input Shaft Outer Asm

D6 2nd Gear; Output Shaft 1/3/4/2 Asm

Input Shaft Outer

D6 1st Gear; Output Shaft 1/3/4/2 Asm

D6 Output Shaft 1/3/4/2 Asm

A5 02 03 03 - N0902 - 06 1

A6 02 03 03 - N0902 - 07 1

A7 02 03 03 - N0902 - 08 1

04

A 02 03 04 - N0902 - 01 1

A1 02 03 04 - N0902 - 02 1

B 02 03 04 - N0902 - 03 1

B1 02 03 04 - N0902 - 04 1

C 02 03 04 - N0902 - 05 1

C1 02 03 04 - N0902 - 06 1

D 02 03 04 - N0902 - 07 1

D1 02 03 04 - N0902 - 08 1

05

A 02 03 05 - N0902 - 01 1

x 06

A X 02 03 06 - N0902 - 01 1

B X 02 03 06 - N0902 - 02 1

C X 02 03 06 - N0902 - 03 1

07

A 02 03 07 - N0902 - 01 1

B 02 03 07 - N0902 - 02 1

C 02 03 07 - N0902 - 03 1

D 02 03 07 - N0902 - 04 1

E 02 03 07 - N0902 - 05 1

10

02 03 10 - N0902 - **

15

A 02 03 15 - N0902 - 01 1

B 02 03 15 - N0902 - 02 1

70

02 03 70 - N0902 - **

75

Reverse Transfer Shaft

D6 3rd Gear Synchro Ring; 3rd Gear Asm

D6 5th Gear Syncro Ring; Output Shaft 5/6/R Asm

D6 6th Gear Syncro Ring; Output Shaft 5/6/R Asm

D6 Reverse Transfer Shaft

Drive Adapter

D6 Differential Asm

D6 Drive Adapter, Right

D6 4th Gear Synchro Ring; 4th Gear Asm

D6 Output Shaft 5/6/R Asm

Gears Misc

D6 4th Gear Asm; Output Shaft 1/3/4/2 Asm

D6 6th Gear Asm; Output Shaft 5/6/R Asm

Output Shaft, 5,6 & reverse

Synchronizers

D6 Input Shaft Inner C-Clip; Input Shaft Inner Sub-Asm

Brackets

Snap Rings

Pipes, Hoses, Ducting

D6 Snap-ring, 5th Gear; Output Shaft 5/6/R Asm

D6 4th Gear; 4th Gear Asm

D6 3rd Gear; 3rd Gear Asm

D6 Output Shaft 5/6/R; Output Shaft 5/6/R Asm

D6 Reverse Gear; Reverse Gear Asm

D6 5th Gear; 5th Gear Asm

D6 6th Gear; 6th Gear Asm

D6 5th Gear Asm; Output Shaft 5/6/R Asm

D6 Reverse Gear Asm; Output Shaft 5/6/R Asm

D6 Drive Adapter, Left

D6 Reverse Gear Syncro Ring; Reverse Gear Asm
02 03 75 - N0902 - **

80

A 02 03 80 - N0902 - 01 2

85

02 03 85 - N0902 - **

90

A 02 03 90 - N0902 - 01 1

B 02 03 90 - N0902 - 02 1

C 02 03 90 - N0902 - 03 1

D 02 03 90 - N0902 - 04 1

E 02 03 90 - N0902 - 05 1

91

A 02 03 91 - N0902 - 01 1

B 02 03 91 - N0902 - 02 1

92

A 02 03 92 - N0902 - 01 1

B 02 03 92 - N0902 - 02 1

C 02 03 92 - N0902 - 03 1

93

A 02 03 93 - N0902 - 01 1

B 02 03 93 - N0902 - 02 1

C 02 03 93 - N0902 - 03 1

D 02 03 93 - N0902 - 04 1

94

A 02 03 94 - N0902 - 01 1

B 02 03 94 - N0902 - 02 1

C 02 03 94 - N0902 - 03 1

D 02 03 94 - N0902 - 04 1

E 02 03 94 - N0902 - 05 1

F 02 03 94 - N0902 - 06 1

G 02 03 94 - N0902 - 07 1

H 02 03 94 - N0902 - 08 1

I 02 03 94 - N0902 - 09 1

J 02 03 94 - N0902 - 10 1

99

02 03 0 - N0902 - **

04 CLUTCHES: Internal for Gears, Synchronizers, Bands, etc. 

02 04 00 - N0902 - 00

01

02 04 01 - N0902 - **

02

See 05 Launch Clutches 02 04 02 - N0902 - **

03 Clutch & Brake Hubs

D6 Needle Bearing, 2nd Gear; Output Shaft Asm

Face roller - input shafts

D6 Needle Bearing, 4th Gear; Output Shaft Asm

D6 Needle Bearing, 6th Gear; Output Shaft 5/6/R Asm

Miscellaneous

Spraque/One Way Clutches

Clutch Assembly C1/C2

Thrust Roller/Needle Bearings

D6 Needle Bearing, 1st Gear; Output Shaft Asm

D6 Input Shaft Needle Bearing Large; Input Shaft Asm

D6 Input Shaft Needle Bearing Small; Input Shaft Asm

D6 Needle Bearing, 3rd Gear; Output Shaft Asm

D6 Bearing, Tappered; Output Shaft 5/6/R Asm

Radial needle - input shafts

D6 Bearing, Reverse Gear; Output Shaft 5/6/R Asm

D6 Input Shaft Thrust Washer; Input Shaft Asm

D6 Bearing, Top, 5th Gear; Output Shaft 5/6/R Asm

D6 Bearing, Bottom, 5th Gear; Output Shaft 5/6/R Asm

Thrust Bearings/Washers

D6 Top Bearing Shaft; Output Shaft 5/6/R Asm

D6 Bearing Race, 3rd Gear; Output Shaft 1/3/4/2 Asm

D6 Bolt - Drive Adapter

Sealing Elements

Bearings Elements Misc

Boltings

Bearing/Bushings

Roller Bearings

D6 Spacer, 5th/6th Gear; Output Shaft 5/6/R Asm

D6 Bearing Race 2; Output Shaft 1/3/4/2 Asm

D6 Bearing Race, 1st Gear; Output Shaft 1/3/4/2 Asm

D6 Bearing Bottom Large Shaft; Output Shaft 1/3/4/2 Asm

D6 Bearing Race, 4th Gear; Output Shaft 1/3/4/2 Asm

D6 Shaft 1/3/4/2, Washer; Output Shaft Asm

D6 Washer, 3rd/4th; Output Shaft Asm

D6 Bearing, Top, Large Shaft; Output Shaft 1/3/4/2 Asm

03

02 04 03 - N0902 - **

04

02 04 04 - N0902 - 01

05

02 04 05 - N0902 - 01 1

07

A 02 04 07 - N0902 - 01 1

A 02 04 07 - N0902 - 02 1

B 02 04 07 - N0902 - 03 1

C 02 04 07 - N0902 - 04 1

D 02 04 07 - N0902 - 05 1

E 02 04 07 - N0902 - 06 1

F 02 04 07 - N0902 - 07 1

G 02 04 07 - N0902 - 08 1

G1 02 04 07 - N0902 - 09 1

G2 02 04 07 - N0902 - 10 1

G3 02 04 07 - N0902 - 11 3

I 02 04 07 - N0902 - 12 1

J 02 04 07 - N0902 - 13 1

K 02 04 07 - N0902 - 14 1

K1 02 04 07 - N0902 - 15 1

K2 02 04 07 - N0902 - 16 1

K3 02 04 07 - N0902 - 17 3

L 02 04 07 - N0902 - 18 1

L1 02 04 07 - N0902 - 19 1

M 02 04 07 - N0902 - 20 1

M1 02 04 07 - N0902 - 21 1

N 02 04 07 - N0902 - 22 3

O 02 04 07 - N0902 - 23 3

P 02 04 07 - N0902 - 24 3

P1 02 04 07 - N0902 - 25 3

P2 02 04 07 - N0902 - 26 3

D6 Hub, Syncronizer, 6/R; 6/R Hub Asm

Disc & Plates

Clutch & Brake Hubs

D6 Hub/Shift Collar Asm 2/4

D6 Shift Collar, 2/4 Gear; H/SC 2/4 Asm

D6 Detents, Syncronizer 5th Gear; 5th Hub Asm

D6 Retainer, Spring 5th Gear; 5th Hub Asm

D6 5th Gear Synchronizer Hub Asm

D6 Detents, Syncronizer 1/3; H/SC 1/3 Asm

D6 Detents, Syncronizer 6/R Asm; 6/R Hub Asm

D6 Detent Plastic; Detents, Syncronizer 6/R Asm

D6 Detent Spring; Detents, Syncronizer 6/R Asm

Sleeve & Couplers

D6 5th Gear Synchronizer Hub; 5th Hub Asm

D6 Shift Collar, 5th Gear; 5th Hub Asm

D6 Shift Collar, 6/R Gear; 6/R Hub Asm

D6 Syncronizer, 5th Gear

D6 Syncronizer, Intermediate Steel, 2nd Gear

Synchronizers

D6 Synchronizer, Inner Brass, 2nd Gear

D6 6/R Syncronizer Hub Asm

D6 Syncronizer, Outer Brass, 2nd Gear

D6 Synchronizer, Inner, Reverse Gear

D6 Synchronizer, Intermediate, Reverse Gear

D6 Synchronizer, Outer, Reverse Gear

D6 Shift Collar, 1/3 Gear; H/SC 1/3 Asm

D6 Hub, 1/3 Gears; H/SC 1/3 Asm

D6 Hub, 2/4 Gears; H/SC 2/4 Asm

D6 Detents, Syncronizer 2/4; H/SC 2/4 Asm

D6 Hub/Shift Collar 1/3 Asm
P3 02 04 07 - N0902 - 27 3

Q 02 04 07 - N0902 - 28 1

R 02 04 07 - N0902 - 29 1

S 02 04 07 - N0902 - 30 1

T 02 04 07 - N0902 - 31 1

T1 02 04 07 - N0902 - 32 1

U 02 04 07 - N0902 - 33 1

U1 02 04 07 - N0902 - 34 1

09

02 04 09 - N0902 - **

15

A 02 04 15 - N0902 - 01 1

B 02 04 15 - N0902 - 02 1

C 02 04 15 - N0902 - 03 1

D 02 04 15 - N0902 - 04 2

E 02 04 15 - N0902 - 05 2

F 02 04 15 - N0902 - 06 2

G 02 04 15 - N0902 - 07 1

H 02 04 15 - N0902 - 08 1

I 02 04 15 - N0902 - 09 1

J 02 04 15 - N0902 - 10 1

70

02 04 70 - N0902 - **

75

02 04 75 - N0902 - **

80

02 04 80 - N0902 - **

85

A 02 04 85 - N0902 - 01 1

90

A 02 04 90 - N0902 - 01 1

B 02 04 90 - N0902 - 02 1

91

02 04 91 - N0902 - **

92

02 04 92 - N0902 - **

93

02 04 93 - N0902 - **

94

02 04 94 - N0902 - **

99

A 02 04 99 - N0902 - 01 5.56

B 02 04 99 - N0902 - 02 0.02

05

Thrust Bearings/Washers

Thrust Roller/Needle Bearings

D6 Detent Ball; Detents, Syncronizer 6/R Asm

D6 Synchronizer, Inner Brass, 1st Gear

D6 Syncronizer, 3rd Gear Asm

Pistons

Snap Rings

Miscellaneous

LAUNCH CLUTCHES: Torque Converter

Pipes, Hoses, Ducting

D6 Spring, Syncronizer Detent, 5th Gear; 5th Hub Asm

D6 Spring, Syncronizer Detent, 1/3 Gear; H/SC 1/3 Asm

D6 Spring, Syncronizer Detent, 2/4 Gear; H/SC 2/4 Asm

Bearing/Bushings

Annular Roller Bearing - shell asy

Face Roller Bearing - hub asy

Radial lip seal - in situ cover asy

Sealing Elements

Boltings

Roller Bearings

D6 Friction paper; Synchronizer Asm

D6 Synchronizer, Outer Brass, 1st Gear

D6 Synchronizer, Intermediate Steel, 1st Gear

Bearing Elements Misc

D6 Snap-ring, 5th Syncronizer

D6 C-clip, Under Oil Pump

Brackets

D6 Snap-Ring, Input Shaft

D6 Syncronizer, 3rd Gear; Synchronizer 3rd Asm

D6 Syncronizer, 4th Gear Asm

D6 Phenolic Adhesive; synchronizer Asm

D6 Syncronizer, 4th Gear; Synchronizer 4th Asm

D6 Snap-ring, 6/R Syncronizer

D6 C-clip, Under C1/C2

D6 Shim, Input Bearing

D6 Snap-ring, Input Bearing

05

02 05 00 - N0902 - 00

01

02 05 01 - N0902 - **

02

A 02 05 02 - N0902 - 01 1

A1 02 05 02 - N0902 - 02 1

A2 02 05 02 - N0902 - 03 1

A3 02 05 02 - N0902 - 04 1

A4 02 05 02 - N0902 - 05 1

A5 02 05 02 - N0902 - 06 1

A6 02 05 02 - N0902 - 07 1

A7 02 05 02 - N0902 - 08 1

A8 02 05 02 - N0902 - 09 1

A9 02 05 02 - N0902 - 10 1

A10 02 05 02 - N0902 - 11 1

A11 02 05 02 - N0902 - 12 1

A12 02 05 02 - N0902 - 13 5

A13 02 05 02 - N0902 - 14 4

A14 02 05 02 - N0902 - 15 1

A15 02 05 02 - N0902 - 16 1

A16 02 05 02 - N0902 - 17 6

A17 02 05 02 - N0902 - 18 4

A18 02 05 02 - N0902 - 19 1

A19 02 05 02 - N0902 - 20 1

A20 02 05 02 - N0902 - 21 1

A21 02 05 02 - N0902 - 22 1

B 02 05 02 - N0902 - 23 1

B1 02 05 02 - N0902 - 24 1

LAUNCH CLUTCHES: Torque Converter

Torque Converter Assembly

Clutch Assembly C1/C2

D6 Inner Clutch Hub Casting Upper; Welded Hub Asm

D6 Inner Clutch Hub; Welded Hub Asm

D6 Inner Clutch Hub Casting Lower; Welded Hub Asm

D6 C1 Hub Asm; C1/C2 Asm

D6 Outer Hub; C1 Hub Asm

D6 Inner Reaction Plate; Inner Clutch Pack

D6 Center Hub Forging; Center Hub Asm

D6 Center Hub Stamping; Center Hub Asm

D6 C1/C2 Asm

D6 Center Hub Asm; C1/C2 Asm

D6 C1/C2 Welded Hub Asm; C1/C2 Asm

D6 Outer Clutch Hub; Welded Hub Asm

D6 Pusher Plate; Welded Hub Asm

D6 Piston Return Spring Seat w/seal; C1/C2 Asm

D6 Inner Clutch Pack Asm; C1/C2 Asm

D6 Inner Clutch Ring; Inner Clutch Pack

D6 Inner Clutch Disk; Inner Clutch Pack

D6 Piston Return Spring Asm; C1/C2 Asm

D6 Piston w/seal; C1/C2 Asm

D6 Inner Clutch Thrust Surface; C1/C2 Asm

D6 Outer Clutch Pack Asm; C1/C2 Asm

D6 Outer Clutch Ring; Outer Clutch Pack

D6 Outer Clutch Disk; Outer Clutch Pack

D6 Outer Reaction Plate; Outer Clutch Pack
B2 02 05 02 - N0902 - 25 1

C 02 05 02 - N0902 - 26 1

C1 02 05 02 - N0902 - 27 1

C2 02 05 02 - N0902 - 28 1

D 02 05 02 - N0902 - 29 1

03

A 02 05 03 - N0902 - 01 1

A1 02 05 03 - N0902 - 02 1

B 02 05 03 - N0902 - 03 1

B1 02 05 03 - N0902 - 04 1

B2 02 05 03 - N0902 - 05 1

B3 02 05 03 - N0902 - 06 1

04

02 05 04 - N0902 - **

05

02 05 05 - N0902 - **

15

A Thrust Ring Retainer; DMFW Asm 02 05 15 - N0902 - 01 1

B Spring Retainer; Fly Wheel Asm 02 05 15 - N0902 - 02 1

C Spring Washer; Fly Wheel Asm 02 05 15 - N0902 - 03 1

D Spring Stop; Fly Wheel Asm 02 05 15 - N0902 - 04 1

E Spring Stop Cover; Fly Wheel Asm 02 05 15 - N0902 - 05 1

F Steel Ring; Fly Wheel Asm 02 05 15 - N0902 - 06 1

G Ring Retainer; Fly Wheel Asm 02 05 15 - N0902 - 07 1

H 02 05 15 - N0902 - 08 1

I 02 05 15 - N0902 - 09 1

J 02 05 15 - N0902 - 10 1

K 02 05 15 - N0902 - 11 1

L 02 05 15 - N0902 - 12 1

M 02 05 15 - N0902 - 13 1

20

A Spring Asm; DMFW Asm 02 05 20 - N0902 - 01 1

A1 Large Spring; Spring Asm 02 05 20 - N0902 - 02 2

A2 Small Spring; Spring Asm 02 05 20 - N0902 - 03 4

C 02 05 20 - N0902 - 04 1

D 02 05 20 - N0902 - 05 22

70

02 05 70 - N0902 - **

75

02 05 75 - N0902 - **

80

A Rivet; DMFW Asm 02 05 80 - N0902 - 01 8

B Rivet Small; Fly Wheel Asm 02 05 80 - N0902 - 02 3

D6 Piston Snap Ring; C1/C2 Asm 

D6 Snap Ring Outer Clutch; C1/C2 Asm 

D6 Inner Snap Ring; C1/C2 Asm 

D6 Snap-Ring, C1 Hub 

Starter Ring Gear; Fly Wheel Asm

Outer Cover Pan; Fly Wheel Asm

Pipes, Hoses, Ducting

D6 Snap-Ring, Outer shell

Pressure Plate; DMFW Asm

Dual Mass Fly Wheel Asm

Fly Weel Asm; DMFW Asm

D6 Outer Clutch Hub Return Spring; Welded Hud Asm

D6 Cover Center; Outer Shell Asm

D6 Outer Shell Asm; C1/C2 Asm

Brackets

Boltings

Springs

D6 Snap-Ring, Cover C1/C2

D6 C1 Cover w/overmold; C1/C2 Asm

D6 Spring; C1/C2 Spring Plate Asm

D6 Outer Shell; Outer Shell Asm

D6 Center Bearing; C1 Hub Asm

Fly Wheels/Flex Plates/Starter Rings

Snap Rings and Retainers

Fly Weel (stamped); Fly Wheel Asm

B Rivet Small; Fly Wheel Asm 02 05 80 - N0902 - 02 3

85

A 02 05 85 - N0902 - 01 1

B 02 05 85 - N0902 - 02 4

90

A 02 05 90 - N0902 - 01 1

B 02 05 90 - N0902 - 02 1

C 02 05 90 - N0902 - 03 1

D 02 05 90 - N0902 - 04 1

E 02 05 90 - N0902 - 05 1

99

A 02 05 99 - N0902 - 01 51

B 02 05 99 - N0902 - 02 18

00

A 02 05 00 - N0902 - 00 1

x 06 OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism, Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.

02 06 00 - N0902 - 00

X 01

A X 02 06 01 - N0902 - 01 1

B X 02 06 01 - N0902 - 02 1

X 02

A Pan & Gasket Asy for Oil Pump X 02 06 02 - N0902 - 01

X 03

A X 02 06 03 - N0902 - 01 1

B X 02 06 03 - N0902 - 02 1

C X 02 06 03 - N0902 - 03 1

X 04

A X 02 06 04 - N0902 - 01 1

05

A 02 06 05 - N0902 - 01 1

X 70

Plastic Ring Bearing; Fly Wheel Asm

Thrust Bearing; DMFW Asm

Bearing Elements

Sealing Ring; C1/C2 Asm

Pipes, Hoses, Ducting

Cover - small external composite

Oil Cooler Asy

Oil Squirter

Squirter Asy

Oil Cooler

Filter Asy large - internal metal and composite

Filter Media - small external

Transmission Assembly of Launch Control Components

Sealing Elements

D6 Center Seal; C1/C2 Asm

Miscellaneous

Oil Pump Assembly

OEM Assembly costs associated with launch controls

Filters

Covers

Pump Asy

Shaft, oil pump

D6 Bearing Thrust; C1 Hub Asm

D6 Friction paper; Clutch Disks

D6 Phenolic Adhesive; Clutch Disks

D6 Bearing - clutch set; Outer Shell Asm

D6 Center Bearing Sleeve; C1/C2 Asm
A X 02 06 70 - N0902 - 01 1

B X 02 06 70 - N0902 - 02 1

X 75

X 02 06 75 - N0902 - **

X 80

A X 02 06 80 - N0902 - 01 11

B X 02 06 80 - N0902 - 02 4

C X 02 06 80 - N0902 - 03 4

X 85

A X 02 06 85 - N0902 - 01 1

B X 02 06 85 - N0902 - 02 1

X 90

X 02 06 90 - N0902 - **

X 99

X 02 06 99 - N0902 - **

07 CONTROLS: Includes Valve Body, Electronics (Solenoids, Switches, Sensors), Wiring Harness, and Shift Compnents (i.e., Forks) 

02 07 00 - N0902 - 00

01

A 02 07 01 - N0902 - 01 1

B 02 07 01 - N0902 - 02 1

B1 02 07 01 - N0902 - 03 1

C 02 07 01 - N0902 - 04 1

D 02 07 01 - N0902 - 05 1

D1 02 07 01 - N0902 - 06 1

E 02 07 01 - N0902 - 07 1

F 02 07 01 - N0902 - 08 2

G 02 07 01 - N0902 - 09 1

H 02 07 01 - N0902 - 10 1

I 02 07 01 - N0902 - 11 1

02

02 07 02 - N0902 - **

03

A 02 07 03 - N0902 - 01 2

B 02 07 03 - N0902 - 02 1

C 02 07 03 - N0902 - 03 1

04

02 07 04 - N0902 - **

05

02 07 05 - N0902 - **

06

A 02 07 06 - N0902 - 01 1

B 02 07 06 - N0902 - 02 1

C 02 07 06 - N0902 - 03 1

Brackets

Boltings

Sealing Elements

Bearing Elements

M6 x 1.0 x 35 - oil pump asy

Wiring Harnesses

M6 x 1.0 x 60 - oil pump asy

Duct - oil feed to internal filter PA66 30GF

Oil Line, small tubular

Solenoids

D6 Valve Body Asm

D6 Outer Valve Body Casting Asm; Valve Body Asm

D6 Spool Valve A

D6 Spool Valve B/C

D6 Spool Valve D

D6 Spool Valve E

D6 Outer Casting, Ball; Valve Body Asm

D6 Inner Valve Body Casting Asm; Valve Body Asm

Sensors

Switches

M6 x 1.0 x 18 - inner oil system

O-ring - oil filter asy

O-ring - oil cooler

Miscellaneous

Valve Body Assembly

Shift Fork Asy 3 - w/balls in steel retainer

D6 Outer Valve Body Casting Asm; Valve Body Asm

D6 Inner Valve Body Casting; Valve Body Asm

D6 Gasket Plate, Vavle Body

Mechanical Controls

D6 inner Valve Body Sensor w/O-ring; Inner VBC Asm

Shift Fork Asy 1 - w/balls in steel retainer

Shift Fork Asy 2 - w/balls in steel retainer

D6 Temperature Sensor

D6 Speed Sensor 01

C 02 07 06 - N0902 - 03 1

D 02 07 06 - N0902 - 04 1

E 02 07 06 - N0902 - 05 1

07

A 02 07 07 - N0902 - 01 1

A1 02 07 07 - N0902 - 02 1

B 02 07 07 - N0902 - 03 1

10

02 07 10 - N0902 - 01

20

A 02 07 20 - N0902 - 01 1

B 02 07 20 - N0902 - 02 3

C 02 07 20 - N0902 - 03 5

25

A 02 07 25 - N0902 - 01 5

B 02 07 25 - N0902 - 02 2

C 02 07 25 - N0902 - 03 2

D 02 07 25 - N0902 - 04 2

75

B 02 07 75 - N0902 - 01 2

80

A 02 07 80 - N0902 - 01 1

B 02 07 80 - N0902 - 02 2

C 02 07 80 - N0902 - 03 1

85

A 02 07 85 - N0902 - 01 1

B 02 07 85 - N0902 - 02 1

C 02 07 85 - N0902 - 03 4

D 02 07 85 - N0902 - 04 2

90

A 02 07 90 - N0902 - 01 2

B 02 07 90 - N0902 - 02 6

C 02 07 90 - N0902 - 03 12

D6 Outer Casting, O-Ring; Outer Casting, Plug Asm

Race Large, Shift Forks 

Ball Bearing Large, Shift Forks 

Race Small, Shift Forks 

Bearing Elements

Sealing Elements

Bracket - shift lever

Shift Lever

Shift Fork Asy 3 - w/balls in steel retainer

Shift Fork Asy 4 - w/balls in steel retainer

D6 Outer Casting, Plug; Outer Casting, Plug Asm

D6 Outer Casting, Plug Asm

D6 Bolt - Gasket Plate, Solenoids

Brackets

Boltings

D6 O-ring, Small, spool valve C retaining plug

D6 O-ring, Middle Valve Body; Vlv Bdy Asm

D6 Bolt - Valve Body Castings; Vlv Bdy Asm

Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

D6 Retaining Key, Spool Valve

D6 Spring, Cup Valve

D6 Spring, Spool Valve A/B/C/D/E

Springs

D6 Outer Casting Spring

Plugs and Cups

Accumulator Assemblies

D6 Inner Valve Body Dowel Pin; Inner VBC Asm

D6 Inner Valve Body Sensor Retainer; Inner VBC Asm

D6 Die cut gasket paper w/adhesive; Gasket Plate

D6 Cup Valve, Outer Valve Body

D6 Bolt - Temperature Sensor - M6 x 1.0 x 22 

D6 Retaining Plug, Spool Valve B/C
D Ball Bearing Small, Shift Forks 02 07 90 - N0902 - 04 36

E 02 07 90 - N0902 - 05 2

F 02 07 90 - N0902 - 06 6

99

A 02 07 99 - N0902 - 01 8

B 02 07 99 - N0902 - 02 8

C 02 07 99 - N0902 - 03 4

D 02 07 99 - N0902 - 04 13

08 CONTROLLER: Including Mechatronic Unit and all integrated components (Some overlap of Controls might occur and will be noted)

02 08 00 - N0902 - 00

01

02 08 01 - N0902 - **

02

A 02 08 02 - N0902 - 01 4

A 02 08 02 - N0902 - 02 1

03

02 08 03 - N0902 - **

04

02 08 04 - N0902 - **

05

A 02 08 05 - N0902 - 01 1

06

A 02 08 06 - N0902 - 01 2

B 02 08 06 - N0902 - 02 1

C 02 08 06 - N0902 - 03 1

D 02 08 06 - N0902 - 04 2

E 02 08 06 - N0902 - 05 4

F 02 08 06 - N0902 - 06 4

G 02 08 06 - N0902 - 07 1

H 02 08 06 - N0902 - 08 1

09

02 08 09 - N0902 - 01 1

10

02 08 10 - N0902 - **

15

02 08 15 - N0902 - **

20

A 02 08 20 - N0902 - 01 4

B 02 08 20 - N0902 - 02 1

25

02 08 25 - N0902 - **

70

02 08 70 - N0902 - **

Solenoids

D6 Harness, Valve Body

D6 Piston, Multiplexer

D6 Spring, Shift Solenoid

D6 Ball Seat, Multiplexer

D6 Coolant Control Valve

Epoxy Glue, Shift Forks

D6 Filter; Inner VBC Asm

Switches

D6 Multiplexer, Solenoid

Sensors

Controller

D6 Clutch Control Valve

Magnet, Shift Forks

Miscellaneous

Wiring Harness

Magnet Cover, Shift Forks

Valves

D6 Shift Solenoid

Cage Large, Shift Forks 

Cage Small, Shift Forks 

D6 Ball, Multiplexer

TBD

Pipes, Hoses, Ducting

D6 Oil Pressure Control Valve

D6 Pressure Safety Valves

D6 Ball, Shift Soenoid

D6 Ball Seat, Shift Solenoid

D6 Spring, Multiplexer

Pistons

TBD

Springs

Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

02 08 70 - N0902 - **

75

A 02 08 75 - N0902 - 01 1

B 02 08 75 - N0902 - 02 1

80

A 02 08 80 - N0902 - 01 4

B 02 08 80 - N0902 - 02 4

C 02 08 80 - N0902 - 03 12

D 02 08 80 - N0902 - 04 2

E 02 08 80 - N0902 - 05 4

F 02 08 80 - N0902 - 06 8

85

A 02 08 85 - N0902 - 01 1

B 02 08 85 - N0902 - 02 4

C 02 08 85 - N0902 - 03 1

D 02 08 85 - N0902 - 04 1

E 02 08 85 - N0902 - 04 1

90

02 08 90 - N0902 - **

99

02 08 99 - N0902 - **

09 PARK MECHANISM: Includes Park & Lock Pawl Mechanism and Actuating Levers

02 09 00 - N0902 - 00

01

A 02 09 01 - N0902 - 01 1

02

A 02 09 02 - N0902 - 01 1

03

A 02 09 03 - N0902 - 01 1

B 02 09 03 - N0902 - 02 1

04

02 09 04 - N0902 - **

25

D6 O-ring, Solenoid

D6 Bolt - Shift Solenoid

D6 Bolt - Small, Solenoids

Boltings

D6 Bottom Bracket, Multiplexer

D6 O-ring, Large, Multiplexer

D6 Bolt - Clutch Control Valves

D6 Gasket, Clutch Control Valves

Sealing Elements

Bearing Elements

Miscellaneous

D6 O-ring, Small, Shift Solenoid

TBD

D6 Spring; Park Pawl Asm

D6 O-ring, Small, Multiplexer

D6 Park Pawl; Park Pawl Asm

D6 Pin, Large, Park Pawl; Park Pawl Asm

Rods/Shafts/Pins

Springs

Pawls

D6 Park Pawl Asm

D6 Top Bracket, Multiplexer

Brackets

D6 Bolt - Top Bracket, Multiplexer

D6 Bolt - Harness, Valve Body

D6 Bolt - Control Module

Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)
A 02 09 25 - N0902 - 01 1

70

02 09 70 - N0902 - **

75

A 02 09 75 - N0902 - 01 1

B 02 09 75 - N0902 - 02 1

80

A 02 09 80 - N0902 - 01 2

B 02 09 80 - N0902 - 02 1

85

02 09 85 - N0902 - **

90

02 09 90 - N0902 - **

99

02 09 99 - N0902 - **

10

02 10 00 - N0902 - 00

01

02 10 01 - N0902 - **

02

02 10 02 - N0902 - **

03

02 10 03 - N0902 - **

04

02 10 04 - N0902 - **

05

02 10 05 - N0902 - **

70

02 10 70 - N0902 - **

75

02 10 75 - N0902 - **

80

02 10 80 - N0902 - **

85

02 10 85 - N0902 - **

90

02 10 90 - N0902 - **

99

02 10 99 - N0902 - **

Sealing Elements

Brackets

Boltings

D6 Bolt - Park Pawl

D6 Bolt - Park Pawl, 12pt

Miscellaneous

Sealing Elements

Pipes, Hoses, Ducting

Bearing Elements

MISCELLANEOUS:

Bearing Elements

Miscellaneous

D6 Spring Retainer, Park Pawl; Park Pawl Asm

D6 Park Lever Asm; Park Pawl Asm

D6 Bracket Park Pawl, Stamped; Park Pawl Asm

Pipes, Hoses, Ducting

Brackets (& Levers)

Boltings (Includes Nuts, Clips, Retainers, etc)
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmissio

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: OEM Assembly costs associated with launch controls

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

1

OEM Assembly costs associated with 

launch controls 020500-N0902-00 1

Assembly C1/C2 Asm, C1 

Hub, snap rings x3, outer 

shell and cover together.

2 D6 C1/C2 Asm 020502-N0902-01 1

Assemble welded hub, 

center bearing, seal 

ring,piston spring seat, 

piston, snap rings x3, thrust 

surface, clutch packs x2 

and center hub together.

GENERAL COMPONENT INFORMATION

Dual Mass Fly Wheel Asm 020503-N0902-01 1 Install dual mas flywheel

0

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

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

0

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

1 D6 C1/C2 Welded Hub Asm; C1/C2 Asm 020502-N0902-02 1 Manufactured

2 D6 Center Bearing Sleeve; C1/C2 Asm 020590-N0902-05a 1 Manufactured

3 Sealing Ring; C1/C2 Asm 020585-N0902-01 4 Manufactured

4

D6 Piston Return Spring Seat w/seal; 

C1/C2 Asm 020502-N0902-08a 1 Manufactured

5 D6 Piston Return Spring Asm; C1/C2 Asm 020502-N0902-09a 1 Manufactured

6 D6 Piston w/seal; C1/C2 Asm 020502-N0902-10a 1 Manufactured

7 D6 Piston Snap Ring; C1/C2 Asm 020515-N0902-08 1 Commodity
8

D6 Inner Clutch Thrust Surface; C1/C2 

Asm 020502-N0902-11 1 Manufactured

9 D6 Outer Clutch Pack Asm; C1/C2 Asm 020502-N0902-12 1 Manufactured

10 D6 Snap Ring Outer Clutch; C1/C2 Asm 020515-N0902-09 1 Commodity

11 D6 Inner Clutch Pack Asm; C1/C2 Asm 020502-N0902-16 1 Manufactured

12 D6 Inner Snap Ring; C1/C2 Asm 020515-N0902-10 1 Commodity

13 D6 Center Hub Asm; C1/C2 Asm 020502-N0902-20 1 Manufactured

14 D6 C1/C2 Asm 020502-N0902-01 1 Manufactured

15 D6 C1 Hub Asm 020502-N0902-23a 1 Manufactured

16 D6 Snap-Ring, C1 Hub 020515-N0902-11 1 Commodity

17 D6 Outer Shell Asm; C1/C2 Asm 020502-N0902-26a 1 Manufactured

18 D6 Snap-Ring, Outer shell 020515-N0902-12 1 Commodity

19 D6 C1 Cover w/overmold; C1/C2 Asm 020502-N0902-29a 1 Manufactured

20 D6 Snap-Ring, Cover C1/C2 020515-N0902-13 1 Commodity

0

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020500-N0902-00

bly costs associated with launch controls

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 116 2 1

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 138 4 1

GENERAL MANUFACTURING INFORMATION

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 138 1 1

#### 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

SAC

SAC

SAC

SAC

SAC

SAC

S
SAC

SAC

S

SAC

S

SAC

SAC

SAC

S

SAC

S

SAC

S

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8X8X8

Parts/Layer: 30 

Number of Layers: 4

t size as Option #1. (Mike S. 020909)
PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 1.787 $0.00 $83.31 $150.21 $150.21 $0.00 $1.43 $1.29 $2.73 0.00% 0.00% 0.00% 0.00%

1 0.120 $0.00 $83.31 $150.21 $150.21 $0.00 $2.41 $1.08 $3.49 0.00% 0.00% 0.00% 0.00%

47

450,000

1

450,000

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.60 $1.08 $1.69 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Material Labor Burden TMC Scrap SG&A Profit ED&T

T1 or OEM Total Manufacturing Cost: $86.47 $4.44 $3.46 $94.38 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00%

(SAC) &T1 or OEM Mark-Up Values: (85.35) ----- ----- ----- $0.00 $0.00 $0.00 $0.00

Base Cost Impact to Vehicle: $1.12 $4.44 $3.46 $9.03 $0.00 $0.00 $0.00 $0.00

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: OEM Assembly, Mark-up Applied @ Bottom.

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $2.73 $2.73 $0.00 $1.43 $1.29 $2.73 $0.00

0.00% $0.00 $3.49 $3.49 $0.00 $2.41 $1.08 $3.49 $0.00

North America

North America

FOB Ship Point

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $1.69 $1.69 $0.00 $0.60 $1.08 $1.69 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$12.90 $12.90 $0.00 $12.90 $12.90 $12.90

$2.27 $2.27 $0.00 $2.27 $2.27 $2.27

$0.81 $0.20 $0.00 $0.81 $0.81 $0.81

$2.12 $2.12 $0.00 $2.12 $2.12 $2.12

$2.42 $2.42 $0.00 $2.42 $2.42 $2.42

$1.61 $1.61 $0.00 $1.61 $1.61 $1.61

$0.00 $0.12 $0.00 $0.12 $0.12 $0.12
$0.15 $0.15 $0.00 $0.15 $0.15 $0.15

$17.32 $17.32 $0.00 $17.32 $17.32 $17.32

$0.00 $0.20 $0.00 $0.20 $0.20 $0.20

$16.67 $16.67 $0.00 $16.67 $16.67 $16.67

$0.00 $0.13 $0.00 $0.13 $0.13 $0.13

$5.51 $5.51 $0.00 $5.51 $5.51 $5.51

$3.49 $3.49 $0.00 $3.49 $3.49 $3.49

$10.10 $10.10 $0.00 $10.10 $10.10 $10.10

$0.00 $0.05 $0.00 $0.05 $0.05 $0.05

$6.13 $6.13 $0.00 $6.13 $6.13 $6.13

$0.00 $0.27 $0.00 $0.27 $0.27 $0.27

$3.86 $3.86 $0.00 $3.86 $3.86 $3.86

$0.00 $0.35 $0.00 $0.35 $0.35 $0.35

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$86.47 $4.44 $3.46 $94.38 $0.00

Total 

Mark-up $94.38

$0.00 $94.38

0.00%

$0.00

$0.00 $9.03 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $9.03

3

Notes: 

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

3

1

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447
31

Notes: 

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

31

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.
SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00 Two assembly stations within the transmission assembly line with lift assists, 

hand tools and means for verification as needed.

$0.00 $0.00 $0.00 $0.00 Four assembly stations within the transmission assembly line with lift assists, 

hand tools and means for verification as needed.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Assembly station within the transmission assembly line with lift assists, hand 

tools and means for verification as needed.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00
SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$94.38

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.
Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Hand tools, lift assists and gauges as 

needed. 5 2 10 100 47 4700 96 37.60 85%

Hand tools, lift assists and gauges as 

needed. 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

Hand tools, lift assists and gauges as 

needed. 5 2 10 100 47 4700 96 37.60 85%

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

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 62 - 1 31 1.0 1.0 116 31.00 2.00

113 31.96 104 - 1 26 1.0 1.0 138 26.00 4.00

um Calculated Cycles Time Project Process Requirement

113 31.96 - - 1 26 1.0 1.0 138 26.00 1.00

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00



Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmissio

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 C1 Cover w/overmold; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

1 0

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

3 D6 C1 Cover w/overmold; C1/C2 Asm 020502-N0902-29a 1 Stamp

1 D6 C1 Cover w/overmold; C1/C2 Asm 020502-N0902-29b 1

Assemble center seal and 

overmold.

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

GENERAL COMPONENT INFORMATION

0

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

D6 Center Seal; C1/C2 Asm 020585-N0902-01 1 Commodity

0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-29

r w/overmold; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 300 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 288 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

GENERAL MANUFACTURING INFORMATION

#### 1 1

S

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8X8X8

Parts/Layer: 30 

Number of Layers: 4

t size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 1.787 $0.65 $42.18 $125.10 $125.10 $1.16 $0.14 $0.42 $1.72 0.00% 0.00% 0.00% 0.00%

1 0.120 $1.32 $42.18 $125.10 $125.10 $0.16 $0.15 $0.43 $0.74 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

9,574

10

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $2.22 $0.29 $0.85 $3.36 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.22 $0.20 $0.03

Base Cost Impact to Vehicle: $2.22 $0.29 $0.85 $3.36 $0.02 $0.22 $0.20 $0.03
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.036 $143,617 0.00% 4,500,000 60 5.00% $300 479 120 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.036

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $1.72 $1.72 $1.16 $0.14 $0.42 $1.72 $0.00

0.00% $0.00 $0.74 $0.74 $0.16 $0.15 $0.43 $0.74 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT

North America

North America

FOB Ship Point

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.90 $0.00 $0.90 $0.90 $0.90

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$2.22 $0.29 $0.85 $3.36 $0.00

Total 

Mark-up $3.36

$0.00 $3.36

14.00%

$0.47

$0.47 $3.83 $0 $0

Packaging Cost: $0.04

3

Notes: 

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

3

1
Net Cost Impact to Vehicle: $3.86

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Large prog die press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Thermoset molding press supported by material extrusion equipment.

$0.00 $0.00 $0.00 $0.00

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$3.36

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Minimum Calculated Cycles Time 

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 12 - 1 12 1.0 1.0 300 12.00 1.00

113 31.96 13 - 1 13 1.0 1.0 288 12.50 1.00

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00



Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmissio

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Outer Shell Asm; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

1 T1 D6 Outer Shell Asm; C1/C2 Asm 020502-N0902-26a 1

Stack components and 

weld together.

D6 Outer Shell Asm; C1/C2 Asm 020502-N0902-26b 1

Assembly bearing to sub 

assembly.

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

3 D6 Outer Shell; Outer Shell Asm 020502-N0902-27 1 Stamp

1 D6 Cover Center; Outer Shell Asm 020502-N0902-28a 1 Forge

GENERAL COMPONENT INFORMATION

1 D6 Cover Center; Outer Shell Asm 020502-N0902-28a 1 Forge

2 D6 Cover Center; Outer Shell Asm 020502-N0902-28b 1 Turn

2 D6 Cover Center; Outer Shell Asm 020502-N0902-28c 1 Roll

2 D6 Cover Center; Outer Shell Asm 020502-N0902-28d 1 Polish

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

0

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

D6 Bearing - clutch set; Outer Shell Asm 020590-N0902-04 1 Commodity

0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00
Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-26

ell Asm; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech. Assembly, LC 514 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech. Assembly, LC 400 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 375 1 1

T1 Assembly, Mark-up Applied HC-Steel-1000S, Coil Cut/Punch/Forming Operator Forge, MHC 514 1 1

GENERAL MANUFACTURING INFORMATION

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Forge, MHC 514 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Rot./Lin. Trans. Machining Line, SP 129 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Stamp/Form, MLS, LMC 450 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Grinding, MLS, LMC 327 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

S

"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 
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8X8X8

Parts/Layer: 30 

Number of Layers: 4

t size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)
00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $35.51 $100.19 $100.19 $0.00 $0.07 $0.19 $0.26 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $35.51 $100.19 $100.19 $0.00 $0.09 $0.25 $0.34 0.00% 0.00% 0.00% 0.00%

1 1.677 $0.65 $42.18 $125.10 $125.10 $1.09 $0.11 $0.33 $1.54 0.00% 0.00% 0.00% 0.00%

1 1.010 $0.65 $42.18 $150.09 $150.09 $0.66 $0.08 $0.29 $1.03 0.00% 0.00% 0.00% 0.00%

9,574

10

47

450,000

1

450,000

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 1.010 $0.65 $42.18 $150.09 $150.09 $0.66 $0.08 $0.29 $1.03 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $35.70 $125.00 $125.00 $0.00 $0.28 $0.97 $1.25 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $35.70 $125.10 $125.10 $0.00 $0.08 $0.28 $0.36 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Material Labor Burden TMC Scrap SG&A Profit ED&T

T1 or OEM Total Manufacturing Cost: $2.05 $0.84 $2.46 $5.34 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.35 $0.32 $0.05

Base Cost Impact to Vehicle: $2.05 $0.84 $2.46 $5.34 $0.03 $0.35 $0.32 $0.05

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.036 $143,617 0.00% 4,500,000 60 5.00% $300 479 120 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.036

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Forge, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $0.26 $0.26 $0.00 $0.07 $0.19 $0.26 $0.00

0.00% $0.00 $0.34 $0.34 $0.00 $0.09 $0.25 $0.34 $0.00

0.00% $0.00 $1.54 $1.54 $1.09 $0.11 $0.33 $1.54 $0.00

0.00% $0.00 $1.03 $1.03 $0.66 $0.08 $0.29 $1.03 $0.00

TOOLING & INVESTMENT

North America

North America

FOB Ship Point

ARK-UP COSTS TOTAL COSTS Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

0.00% $0.00 $1.03 $1.03 $0.66 $0.08 $0.29 $1.03 $0.00

0.00% $0.00 $1.25 $1.25 $0.00 $0.28 $0.97 $1.25 $0.00

0.00% $0.00 $0.36 $0.36 $0.00 $0.08 $0.28 $0.36 $0.00

0.00% $0.00 $0.27 $0.27 $0.00 $0.13 $0.14 $0.27 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.30 $0.00 $0.30 $0.30 $0.30

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$2.05 $0.84 $2.46 $5.34 $0.00

3
Total 

Mark-up $5.34

$0.00 $5.34

14.00%

$0.75

$0.75 $6.09 $0 $0

Packaging Cost: $0.04

Net Cost Impact to Vehicle: $6.13

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

Notes: 

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

3

1

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00 Assembly station with manually loaded parts, turn table to present sub-assembly 

to welding station.

$0.00 $0.00 $0.00 $0.00 Manual assembly station with fixture, lock down and press head.

$0.00 $0.00 $0.00 $0.00 Large prog die press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Large forging press and means for induction heating blanks.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Large forging press and means for induction heating blanks.

$0.00 $0.00 $0.00 $0.00 Machining station; means for auto presentation, part manipulation and transfer.

$0.00 $0.00 $0.00 $0.00 Tooth rolling machine with auto load and transfer.

$0.00 $0.00 $0.00 $0.00 Auto feed through grinder/polisher with a feed to end polishing wheel.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

Price per square inch.

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

2
$5.34

alue otherwise there is a computation error.

2

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling; form x2 + trim 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Custom Tooling; form x2 + trim 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

N/A 5 2 10 100 47 4700 96 37.60 85%

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 7 - 1 7 1.0 1.0 514 7.00 1.00

113 31.96 9 - 1 9 1.0 1.0 400 9.00 1.00

113 31.96 10 - 1 10 1.0 1.0 375 9.60 1.00

113 31.96 7 - 1 7 1.0 1.0 514 7.00 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 7 - 1 7 1.0 1.0 514 7.00 1.00

113 31.96 28 - 1 28 1.0 1.0 129 28.00 1.00

113 31.96 8 - 1 8 1.0 1.0 450 8.00 1.00

113 31.96 11 - 1 11 1.0 1.0 327 11.00 1.00

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00



Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmissio

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 C1 Hub Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

1 T1 D6 C1 Hub Asm 020502-N0902-23a 1

Stack components and 

weld together.

D6 C1 Hub Asm 020502-N0902-23b 1

Assembly thrust bearing to 

sub assembly.

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

3 D6 Outer Hub; C1 Hub Asm 020502-N0902-24a 1 Stamp

4 D6 Outer Hub; C1 Hub Asm 020502-N0902-24b 1 Spin Form

GENERAL COMPONENT INFORMATION

4 D6 Outer Hub; C1 Hub Asm 020502-N0902-24b 1 Spin Form

5 D6 Outer Hub; C1 Hub Asm 020502-N0902-24c 1 Punch

1 D6 Center Bearing; C1 Hub Asm 020502-N0902-25a 1 Forge

2 D6 Center Bearing; C1 Hub Asm 020502-N0902-25b 1 Turn

2 D6 Center Bearing; C1 Hub Asm 020502-N0902-25c 1 Broach

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

0

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

D6 Bearing Thrust; C1 Hub Asm 020590-N0902-03 1 Commodity

0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-23

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech. Assembly, LC 225 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech. Assembly, LC 327 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 375 1 1

T1 Assembly, Mark-up Applied Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 164 1 1

GENERAL MANUFACTURING INFORMATION

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 164 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 217 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Forge, MHC 133 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Rot./Lin. Trans. Machining Line, SP 122 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Rot./Lin. Trans. Machining Line, SP 206 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

S

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8X8X8

Parts/Layer: 30 

Number of Layers: 4

t size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 
22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $35.51 $100.19 $100.19 $0.00 $0.16 $0.45 $0.60 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $35.51 $100.19 $100.19 $0.00 $0.11 $0.31 $0.41 0.00% 0.00% 0.00% 0.00%

1 1.909 $0.65 $42.18 $125.10 $125.10 $1.24 $0.11 $0.33 $1.69 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.26 $0.76 $1.02 0.00% 0.00% 0.00% 0.00%

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

9,574

10

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.26 $0.76 $1.02 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.19 $0.58 $0.77 0.00% 0.00% 0.00% 0.00%

1 0.286 $0.65 $42.18 $150.09 $150.09 $0.19 $0.32 $1.13 $1.63 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $35.70 $125.00 $125.00 $0.00 $0.29 $1.02 $1.32 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $35.70 $125.00 $125.00 $0.00 $0.17 $0.61 $0.78 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Material Labor Burden TMC Scrap SG&A Profit ED&T

T1 or OEM Total Manufacturing Cost: $2.03 $1.61 $5.18 $8.82 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.04 $0.57 $0.53 $0.09

Base Cost Impact to Vehicle: $2.03 $1.61 $5.18 $8.82 $0.04 $0.57 $0.53 $0.09

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.036 $143,617 0.00% 4,500,000 60 5.00% $300 479 120 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.036

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Forge, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $0.60 $0.60 $0.00 $0.16 $0.45 $0.60 $0.00

0.00% $0.00 $0.41 $0.41 $0.00 $0.11 $0.31 $0.41 $0.00

0.00% $0.00 $1.69 $1.69 $1.24 $0.11 $0.33 $1.69 $0.00

0.00% $0.00 $1.02 $1.02 $0.00 $0.26 $0.76 $1.02 $0.00

Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT

North America

North America

FOB Ship Point

0.00% $0.00 $1.02 $1.02 $0.00 $0.26 $0.76 $1.02 $0.00

0.00% $0.00 $0.77 $0.77 $0.00 $0.19 $0.58 $0.77 $0.00

0.00% $0.00 $1.63 $1.63 $0.19 $0.32 $1.13 $1.63 $0.00

0.00% $0.00 $1.32 $1.32 $0.00 $0.29 $1.02 $1.32 $0.00

0.00% $0.00 $0.78 $0.78 $0.00 $0.17 $0.61 $0.78 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.60 $0.00 $0.60 $0.60 $0.60

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

3
$2.03 $1.61 $5.18 $8.82 $0.00

Total 

Mark-up $8.82

$0.00 $8.82

14.00%

$1.24

$1.24 $10.06 $0 $0

Packaging Cost: $0.04

Net Cost Impact to Vehicle: $10.10

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

Notes: 

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

3

1

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00 Assembly station with manually loaded parts, turn table to present sub-assembly 

to welding station.

$0.00 $0.00 $0.00 $0.00 Manual assembly station with fixture, lock down and press head.

$0.00 $0.00 $0.00 $0.00 Large prog die press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Spin forming machine with means for auto presentation and fixturing.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Spin forming machine with means for auto presentation and fixturing.

$0.00 $0.00 $0.00 $0.00 Manually operated punch press.

$0.00 $0.00 $0.00 $0.00 Large forging press and means for induction heating blanks.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least two stattions; means for auto presentation, part 

manipulation and transfer between stations.

$0.00 $0.00 $0.00 $0.00 Vertical broach machine with manual load and unload.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

Price per square inch.

SG&A Profit ED&T Mark-up 

Total

2
$0.00 $0.00 $0.00 $0.00

$8.82

alue otherwise there is a computation error.

2

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Minimum Calculated Cycles Time 

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom dies and fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling; form x2 + trim 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 16 - 1 16 1.0 1.0 225 16.00 1.00

113 31.96 11 - 1 11 1.0 1.0 327 11.00 1.00

113 31.96 10 - 1 10 1.0 1.0 375 9.60 1.00

113 31.96 22 - 1 22 1.0 1.0 164 22.00 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 22 - 1 22 1.0 1.0 164 22.00 1.00

113 31.96 17 - 1 17 1.0 1.0 217 16.60 1.00

113 31.96 37 - 1 27 1.0 1.0 133 27.00 1.00 Annealing not required so it was dro

113 31.96 59 - 1 30 1.0 1.0 122 29.50 1.00 Multi station process.

113 31.96 18 - 1 18 1.0 1.0 206 17.50 1.00 Multi station process.

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Annealing not required so it was dropped.

Multi station process.

Multi station process.
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmissio

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Center Hub Asm; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

1 T1 D6 Center Hub Asm; C1/C2 Asm 020502-N0902-20 1

Stack components and 

weld together.

0

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

1 D6 Center Hub Forging; Center Hub Asm 020502-N0902-21a 1 Forge

2 D6 Center Hub Forging; Center Hub Asm 020502-N0902-21b 1 Turn

GENERAL COMPONENT INFORMATION

2 D6 Center Hub Forging; Center Hub Asm 020502-N0902-21b 1 Turn

3

D6 Center Hub Stamping; Center Hub 

Asm 020502-N0902-22a 1 Stamp

4

D6 Center Hub Stamping; Center Hub 

Asm 020502-N0902-22b 1 Spin Form

5

D6 Center Hub Stamping; Center Hub 

Asm 020502-N0902-22c 1 Punch

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

0

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

0

0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00
Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-20

ub Asm; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Stamp/Form, MLS, LMC 257 1 1

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Forge, MHC 240 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Rot./Lin. Trans. Machining Line, SP 176 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable CNC Operator Rot./Lin. Trans. Machining Line, SP 176 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 387 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 171 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 277 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"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 
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8X8X8

Parts/Layer: 30 

Number of Layers: 4

t size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)
00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $35.51 $125.10 $125.10 $0.00 $0.14 $0.49 $0.62 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.180 $0.65 $42.18 $150.09 $150.09 $0.12 $0.18 $0.63 $0.92 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $35.70 $125.00 $125.00 $0.00 $0.20 $0.71 $0.92 0.00% 0.00% 0.00% 0.00%

9,574

10

47

450,000

1

450,000

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $35.70 $125.00 $125.00 $0.00 $0.20 $0.71 $0.92 0.00% 0.00% 0.00% 0.00%

1 0.515 $0.65 $42.18 $125.10 $125.10 $0.33 $0.11 $0.32 $0.77 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.25 $0.73 $0.98 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.15 $0.45 $0.60 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Material Labor Burden TMC Scrap SG&A Profit ED&T

T1 or OEM Total Manufacturing Cost: $0.45 $1.02 $3.33 $4.80 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.31 $0.29 $0.05

Base Cost Impact to Vehicle: $0.45 $1.02 $3.33 $4.80 $0.02 $0.31 $0.29 $0.05

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.036 $143,617 0.00% 4,500,000 60 5.00% $300 479 120 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.036

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Forge, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $0.62 $0.62 $0.00 $0.14 $0.49 $0.62 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.92 $0.92 $0.12 $0.18 $0.63 $0.92 $0.00

0.00% $0.00 $0.92 $0.92 $0.00 $0.20 $0.71 $0.92 $0.00

TOOLING & INVESTMENT

North America

North America

FOB Ship Point

ARK-UP COSTS TOTAL COSTS Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

0.00% $0.00 $0.92 $0.92 $0.00 $0.20 $0.71 $0.92 $0.00

0.00% $0.00 $0.77 $0.77 $0.33 $0.11 $0.32 $0.77 $0.00

0.00% $0.00 $0.98 $0.98 $0.00 $0.25 $0.73 $0.98 $0.00

0.00% $0.00 $0.60 $0.60 $0.00 $0.15 $0.45 $0.60 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.45 $1.02 $3.33 $4.80 $0.00

3
Total 

Mark-up $4.80

$0.00 $4.80

14.00%

$0.67

$0.67 $5.48 $0 $0

Packaging Cost: $0.04

Net Cost Impact to Vehicle: $5.51

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

Notes: 

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

3

1

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00 Assembly station with manually loaded parts, turn table to present sub-assembly 

to welding station.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Large forging press.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least two stattions; means for auto presentation, part 

manipulation and transfer between stations.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 manipulation and transfer between stations.

$0.00 $0.00 $0.00 $0.00 Large prog die press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Spin forming machine with means for auto presentation and fixturing.

$0.00 $0.00 $0.00 $0.00 Manually operated punch press.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

Price per square inch.

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

2
$4.80

alue otherwise there is a computation error.

2

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

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

Custom Tooling; form x2 + trim 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom dies and fixtures. 5 2 10 100 47 4700 96 37.60 85%

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 14 - 1 14 1.0 1.0 257 14.00 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 15 - 1 15 1.0 1.0 240 15.00 1.00

113 31.96 41 - 1 21 1.0 1.0 176 20.50 1.00 Multi station process.

um Calculated Cycles Time Project Process Requirement

113 31.96 41 - 1 21 1.0 1.0 176 20.50 1.00 Multi station process.

113 31.96 9 - 1 9 1.0 1.0 387 9.30 1.00

113 31.96 21 - 1 21 1.0 1.0 171 21.00 1.00

113 31.96 13 - 1 13 1.0 1.0 277 13.00 1.00

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Multi station process.
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmissio

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Inner Clutch Pack Asm; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

1 T1 D6 Inner Clutch Pack Asm; C1/C2 Asm 020502-N0902-16 1 Stack and pack

0

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

1 D6 Inner Clutch Ring; Inner Clutch Pack 020502-N0902-17a 6 Fine Blank

2 D6 Inner Clutch Ring; Inner Clutch Pack 020502-N0902-17b 6 Debur/grind

GENERAL COMPONENT INFORMATION

2 D6 Inner Clutch Ring; Inner Clutch Pack 020502-N0902-17b 6 Debur/grind

3 D6 Inner Clutch Disk; Inner Clutch Pack 020502-N0902-18a 5 Fine Blank

4 D6 Inner Clutch Disk; Inner Clutch Pack 020502-N0902-18b 5 Grind

5 D6 Inner Clutch Disk; Inner Clutch Pack 020502-N0902-18c 5 Assemble friction paper

6 D6 Inner Reaction Plate; Inner Clutch Pack 020502-N0902-19a 1 Fine Blank

7

D6 Outer Reaction Plate; Outer Clutch 

Pack 020502-N0902-19b 1 Debur/grind

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

0

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

1 D6 Friction paper; Synchronizer Asm 020599-N0902-01 35 Commodity

2 D6 Phenolic Adhesive; synchronizer Asm 020599-N0902-02 10 Commodity
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-16

tch Pack Asm; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 257 1 1

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1895 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 2000 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 592 1 5

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1895 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

S

S
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8X8X4

Parts/Layer: 30 

Number of Layers: 5

t size as Option #1. (Mike S. 020909)

Expendable Packaging in Piece Cost:

Packaging Cost Total:
PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.14 $0.12 $0.25 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.572 $0.65 $42.18 $125.10 $125.10 $0.37 $0.02 $0.07 $0.46 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

9,574

10

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

1 0.268 $0.65 $42.18 $125.10 $125.10 $0.17 $0.02 $0.06 $0.26 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $625.50 $0.00 $0.07 $1.06 $1.13 0.00% 0.00% 0.00% 0.00%

1 1.192 $0.65 $42.18 $125.10 $125.10 $0.77 $0.02 $0.07 $0.86 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Material Labor Burden TMC Scrap SG&A Profit ED&T

T1 or OEM Total Manufacturing Cost: $4.33 $1.60 $8.68 $14.60 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.07 $0.95 $0.88 $0.15

Base Cost Impact to Vehicle: $4.33 $1.60 $8.68 $14.60 $0.07 $0.95 $0.88 $0.15

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.027 $107,713 0.00% 4,500,000 60 5.00% $300 359 160 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

ULATIONS: 

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.027

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Fine Blank, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $0.25 $0.25 $0.00 $0.14 $0.12 $0.25 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.46 $2.76 $2.23 $0.13 $0.40 $2.76 $0.00

0.00% $0.00 $0.28 $1.67 $0.00 $0.42 $1.25 $1.67 $0.00

Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT

North America

North America

FOB Ship Point

0.00% $0.00 $0.28 $1.67 $0.00 $0.42 $1.25 $1.67 $0.00

0.00% $0.00 $0.26 $1.29 $0.87 $0.11 $0.31 $1.29 $0.00

0.00% $0.00 $0.28 $1.39 $0.00 $0.35 $1.04 $1.39 $0.00

0.00% $0.00 $1.13 $5.64 $0.00 $0.36 $5.28 $5.64 $0.00

0.00% $0.00 $0.86 $0.86 $0.77 $0.02 $0.07 $0.86 $0.00

0.00% $0.00 $0.28 $0.28 $0.00 $0.07 $0.21 $0.28 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.01 $0.00 $0.35 $0.35 $0.35

$0.00 $0.01 $0.00 $0.10 $0.10 $0.10
Material Labor Burden TMC Scrape

$4.33 $1.60 $8.68 $14.60 $0.00

Total 

Mark-up $14.60

$0.00 $14.60

14.00%

$2.04

$2.04 $16.65 $0 $0

Packaging Cost: $0.03

Net Cost Impact to Vehicle: $16.67

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

Notes: 

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

3

1

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00 Assembly station where parts are stacked and packed.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Large fine blanking press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process.

$0.00 $0.00 $0.00 $0.00 Large fine blanking press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process then through glue application.

$0.00 $0.00 $0.00 $0.00 EOL fedd into automated punch stamp to apply and cut paper from strips.

$0.00 $0.00 $0.00 $0.00 Large fine blanking press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

Price per square inch.

2
SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$14.60

alue otherwise there is a computation error.

2

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

N/A 5 2 10 100 47 4700 96 37.60 85%

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

Custom Tooling 5 2 10 100 47 4700 574 6.27 85%

N/A 5 2 10 100 47 4700 574 6.27 85%

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Minimum Calculated Cycles Time 

N/A 5 2 10 100 47 4700 574 6.27 85%

Custom Tooling 5 2 10 100 47 4700 479 7.52 85%

Custom Fixtures 5 2 10 100 47 4700 479 7.52 85%

Custom dies and fixtures. 5 2 10 100 47 4700 479 7.52 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

N/A 5 2 10 100 47 4700 96 37.60 85%

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 36 - 1 14 1.0 1.0 257 14.00 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

676 5.33 2 - 1 2 1.0 1.0 1895 1.90 1.00

676 5.33 6 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

um Calculated Cycles Time Project Process Requirement

LD places too much time on sort an

676 5.33 6 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

563 6.39 2 - 1 2 1.0 1.0 2000 1.80 1.00

563 6.39 6 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

563 6.39 30 - 1 30 1.0 5.0 592 6.08 1.00 Requires 5 parallel machines to me

113 31.96 2 - 1 2 1.0 1.0 1895 1.90 1.00

113 31.96 6 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Continuous belt driven process

LD places too much time on sort and stack

Continuous belt driven process

Requires 5 parallel machines to meet production volumes.

Continuous belt driven process
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmissio

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Outer Clutch Pack Asm; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

1 T1 D6 Outer Clutch Pack Asm; C1/C2 Asm 020502-N0902-12 1 Stack and pack

0

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

1 D6 Outer Clutch Ring; Outer Clutch Pack 020502-N0902-13a 5 Fine Blank

2 D6 Outer Clutch Ring; Outer Clutch Pack 020502-N0902-13b 5 Debur

GENERAL COMPONENT INFORMATION

2 D6 Outer Clutch Ring; Outer Clutch Pack 020502-N0902-13b 5 Debur

3 D6 Outer Clutch Disk; Outer Clutch Pack 020502-N0902-14a 4 Fine Blank

4 D6 Outer Clutch Disk; Outer Clutch Pack 020502-N0902-14b 4 Grind

5 D6 Outer Clutch Disk; Outer Clutch Pack 020502-N0902-14c 4 Assemble friction paper

6

D6 Outer Reaction Plate; Outer Clutch 

Pack 020502-N0902-15a 1 Fine Blank

7

D6 Outer Reaction Plate; Outer Clutch 

Pack 020502-N0902-15b 1 Debur

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

0

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

1 D6 Friction paper; Synchronizer Asm 020599-N0902-01 16 Commodity

2 D6 Phenolic Adhesive; synchronizer Asm 020599-N0902-02 8 Commodity
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sa

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(3

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-12

utch Pack Asm; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 327 1 1

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 2000 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1895 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 576 1 4

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1714 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 600 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

S 

S 
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8X8X4

Parts/Layer: 30 

Number of Layers: 5

t size as Option #1. (Mike S. 020909)

Expendable Packaging in Piece Cost:

Packaging Cost Total:
PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.11 $0.09 $0.20 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 1.680 $0.65 $42.18 $125.10 $125.10 $1.09 $0.02 $0.06 $1.18 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

1 0.426 $0.65 $42.18 $125.10 $125.10 $0.28 $0.02 $0.07 $0.37 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $500.40 $0.00 $0.07 $0.87 $0.94 0.00% 0.00% 0.00% 0.00%

1 1.498 $0.65 $42.18 $125.10 $125.10 $0.97 $0.02 $0.07 $1.07 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.07 $0.21 $0.28 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Material Labor Burden TMC Scrap SG&A Profit ED&T

T1 or OEM Total Manufacturing Cost: $7.54 $1.32 $6.30 $15.17 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.08 $0.99 $0.91 $0.15

Base Cost Impact to Vehicle: $7.54 $1.32 $6.30 $15.17 $0.08 $0.99 $0.91 $0.15

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.027 $107,713 0.00% 4,500,000 60 5.00% $300 359 160 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

ULATIONS: 

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.027

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Fine Blank, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $0.20 $0.20 $0.00 $0.11 $0.09 $0.20 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $1.18 $5.88 $5.46 $0.11 $0.31 $5.88 $0.00

0.00% $0.00 $0.28 $1.39 $0.00 $0.35 $1.04 $1.39 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $0.28 $1.39 $0.00 $0.35 $1.04 $1.39 $0.00

0.00% $0.00 $0.37 $1.46 $1.11 $0.09 $0.26 $1.46 $0.00

0.00% $0.00 $0.28 $1.12 $0.00 $0.28 $0.83 $1.12 $0.00

0.00% $0.00 $0.94 $3.77 $0.00 $0.29 $3.48 $3.77 $0.00

0.00% $0.00 $1.07 $1.07 $0.97 $0.02 $0.07 $1.07 $0.00

0.00% $0.00 $0.28 $0.28 $0.00 $0.07 $0.21 $0.28 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.01 $0.16 $0.00 $0.00 $0.00

$0.00 $0.01 $0.08 $0.00 $0.00 $0.00
Material Labor Burden TMC Scrape

$7.54 $1.32 $6.30 $15.17 $0.00

Total 

Mark-up $15.17

$0.00 $15.17

14.00%

$2.12

$2.12 $17.29 $0 $0

Packaging Cost: $0.03

Net Cost Impact to Vehicle: $17.32

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

Notes: 

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

3

1

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00 Assembly station where parts are stacked and packed.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Large fine blanking press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process.

$0.00 $0.00 $0.00 $0.00 Large fine blanking press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process then through glue application.

$0.00 $0.00 $0.00 $0.00 EOL fedd into automated punch stamp to apply and cut paper from strips.

$0.00 $0.00 $0.00 $0.00 Large fine blanking press with means for auto feed and straighten and drop into 

hopper.

$0.00 $0.00 $0.00 $0.00 Hopper feed into two sided grinding process.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

Price per square inch.

2
SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$15.17

alue otherwise there is a computation error.

2

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

N/A 5 2 10 100 47 4700 96 37.60 85%

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

Custom Tooling 5 2 10 100 47 4700 479 7.52 85%

N/A 5 2 10 100 47 4700 479 7.52 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

N/A 5 2 10 100 47 4700 479 7.52 85%

Custom Tooling 5 2 10 100 47 4700 383 9.40 85%

Custom Fixtures 5 2 10 100 47 4700 383 9.40 85%

Custom dies and fixtures. 5 2 10 100 47 4700 383 9.40 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

N/A 5 2 10 100 47 4700 96 37.60 85%

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 39 - 1 11 1.0 1.0 327 11.00 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

563 6.39 2 - 1 2 1.0 1.0 2000 1.80 1.00

563 6.39 7 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

LD assume too much time for hand

um Calculated Cycles Time Project Process Requirement

563 6.39 7 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

451 7.99 2 - 1 2 1.0 1.0 1895 1.90 1.00

451 7.99 7 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

451 7.99 25 - 1 25 1.0 4.0 576 6.25 1.00 Requires four parallel machines to 

113 31.96 2 - 1 2 1.0 1.0 1714 2.10 1.00

113 31.96 6 - 1 6 1.0 1.0 600 6.00 1.00 Continuous belt driven process

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Continuous belt driven process

LD assume too much time for handling and stacking.

Continuous belt driven process

Requires four parallel machines to meet production volumes.

Continuous belt driven process
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Inner Clutch Thrust Surface; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1

D6 Inner Clutch Thrust Surface; C1/C2 

Asm 020502-N0902-11 1 Injection mold

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

GENERAL COMPONENT INFORMATION

1 0

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

1 0

Pallet Options

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

Investment $200 US funds (Mike S.)
Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-11

tch Thrust Surface; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 1500 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

GENERAL MANUFACTURING INFORMATION

#### 1 1

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.25

Parts/Layer: 1,152 

Number of Layers: 6

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.015 $1.74 $43.52 $100.01 $100.01 $0.03 $0.03 $0.07 $0.12 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.03 $0.03 $0.07 $0.12 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.01 $0.01 $0.00

Base Cost Impact to Vehicle: $0.03 $0.03 $0.07 $0.12 $0.00 $0.01 $0.01 $0.00
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.001 $5,818 0.00% 4,500,000 60 5.00% $700 8 6912 6

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

able Packaging in Piece Cost: $0.01 $0.00 0 $10.00 7 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.012

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Inject. Mold, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.12 $0.12 $0.03 $0.03 $0.07 $0.12 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.03 $0.03 $0.07 $0.12 $0.00

Total 

Mark-up $0.12

$0.00 $0.12

14.00%

$0.02

$0.02 $0.14 $0 $0

Packaging Cost: $0.01

Net Cost Impact to Vehicle: $0.15

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium injection molding press.

$0.00 $0.00 $0.00 $0.00

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.12

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise otherwise there is a computation there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Eight cavity tooling 5 2 10 100 47 4700 96 37.60 85%

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 8 19 1.0 1.0 1500 2.40 1.00 LD give price per part

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


LD give price per part
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Piston w/seal; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 D6 Piston w/seal; C1/C2 Asm 020502-N0902-10a 1 Stamp

1 D6 Piston w/seal; C1/C2 Asm 020502-N0902-10b 1 Debur

1 D6 Piston w/seal; C1/C2 Asm 020502-N0902-10c 1 Overmold

GENERAL COMPONENT INFORMATION

1 D6 Piston w/seal; C1/C2 Asm 020502-N0902-10c 1 Overmold

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-10

seal; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 2000 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 450 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator Stamp/Form, MLS, LMC 404 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator Stamp/Form, MLS, LMC 404 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.25

Parts/Layer: 1,152 

Number of Layers: 6

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.314 $0.65 $42.18 $125.10 $125.10 $0.20 $0.02 $0.06 $0.29 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.09 $0.28 $0.37 0.00% 0.00% 0.00% 0.00%

2 0.013 $1.32 $43.52 $125.10 $250.20 $0.02 $0.11 $0.62 $0.74 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

2 0.013 $1.32 $43.52 $125.10 $250.20 $0.02 $0.11 $0.62 $0.74 0.00% 0.00% 0.00% 0.00%

0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.22 $0.22 $0.96 $1.40 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.09 $0.08 $0.01

Base Cost Impact to Vehicle: $0.22 $0.22 $0.96 $1.40 $0.01 $0.09 $0.08 $0.01
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.001 $5,818 0.00% 4,500,000 60 5.00% $700 8 6912 6

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

able Packaging in Piece Cost: $0.01 $0.00 0 $10.00 7 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.012

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.29 $0.29 $0.20 $0.02 $0.06 $0.29 $0.00

0.00% $0.00 $0.37 $0.37 $0.00 $0.09 $0.28 $0.37 $0.00

0.00% $0.00 $0.74 $0.74 $0.02 $0.11 $0.62 $0.74 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $0.74 $0.74 $0.02 $0.11 $0.62 $0.74 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.22 $0.22 $0.96 $1.40 $0.00

Total 

Mark-up $1.40

$0.00 $1.40

14.00%

$0.20

$0.20 $1.60 $0 $0

Packaging Cost: $0.01

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $1.61

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium stamping press.

$0.00 $0.00 $0.00 $0.00 Tubling equipment with abrasive media.

$0.00 $0.00 $0.00 $0.00 Termoset heat press and rubber extrusion equipment operated in parallel.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Termoset heat press and rubber extrusion equipment operated in parallel.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$1.40

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tooling 5 2 10 100 47 4700 96 37.60 85%

N/A 5 2 10 100 47 4700 96 37.60 85%

Multi-cavity tooling 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

Multi-cavity tooling 5 2 10 100 47 4700 96 37.60 85%

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 2000 1.80 1.00

113 31.96 8 - 450 3,600 1.0 1.0 450 8.00 1.00 LD gives price per part

113 31.96 9 - 4 36 2.0 1.0 404 8.90 1.00 LD gives price per part

um Calculated Cycles Time Project Process Requirement

113 31.96 9 - 4 36 2.0 1.0 404 8.90 1.00 LD gives price per part

0 #DIV/0! - - 1 - 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


LD gives price per part

LD gives price per part
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 C1/C2 Spring Plate Asm; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 D6 Piston Return Spring Asm; C1/C2 

Asm 020502-N0902-09a 1

Assemble plate and springs 

together

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

1 D6 C1/C2 Spring Plate 020502-N0902-09a 2 Stamp

1 D6 C1/C2 Spring Plate 020502-N0902-09a 1 Debur

0

GENERAL COMPONENT INFORMATION

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 D6 Spring; C1/C2 Spring Plate Asm 020520-N0902-05 22 Commodity

Pallet Options
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30
Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-09

pring Plate Asm; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 120 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 2000 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 400 1 1

#### 1 1

GENERAL MANUFACTURING INFORMATION

Material Estimate + Actual Component Assembly Process)

#### 1 1

S

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x2

Parts/Layer: 144

Number of Layers: 6

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $35.51 $45.00 $45.00 $0.00 $0.30 $0.38 $0.67 0.00% 0.00% 0.00% 0.00%

1 0.097 $0.65 $42.18 $125.10 $125.10 $0.06 $0.02 $0.06 $0.15 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.11 $0.31 $0.42 0.00% 0.00% 0.00% 0.00%

0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.79 $0.44 $0.81 $2.04 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.13 $0.12 $0.02

Base Cost Impact to Vehicle: $0.79 $0.44 $0.81 $2.04 $0.01 $0.13 $0.12 $0.02
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.012 $46,543 0.00% 4,500,000 60 5.00% $700 66 864 6

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

able Packaging in Piece Cost: $0.08 $0.00 0 $10.00 7 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.093

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $0.67 $0.67 $0.00 $0.30 $0.38 $0.67 $0.00

0.00% $0.00 $0.15 $0.29 $0.13 $0.04 $0.13 $0.29 $0.00

0.00% $0.00 $0.42 $0.42 $0.00 $0.11 $0.31 $0.42 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.03 $0.00 $0.66 $0.66 $0.66

Material Labor Burden TMC Scrape

$0.79 $0.44 $0.81 $2.04 $0.00

Total 

Mark-up $2.04

$0.00 $2.04

14.00%

$0.29

$0.29 $2.33 $0 $0

Packaging Cost: $0.09

Net Cost Impact to Vehicle: $2.42

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00 Automated assembly equipment with means to auto feed plates,bowl feed 

springs and press head to press together..

$0.00 $0.00 $0.00 $0.00 Medium stamping press.

$0.00 $0.00 $0.00 $0.00 Tubling equipment with abrasive media.

$0.00 $0.00 $0.00 $0.00

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$2.04

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise otherwise there is a computation there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Custom feeders and fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom tooling. 5 2 10 100 47 4700 191 18.80 85%

N/A 5 2 10 100 47 4700 96 37.60 85%

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

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 56 - 1 30 1.0 1.0 120 30.00 1.00

225 15.98 2 - 1 2 1.0 1.0 2000 1.80 1.00

113 31.96 9 - 400 3,600 1.0 1.0 400 9.00 1.00 LD gives price per part

0 #DIV/0! - - 1 - 1.0 #DIV/0! #DIV/0! 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - 1 - 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


LD gives price per part
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Piston Return Spring Seat w/seal; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1

D6 Piston Return Spring Seat w/seal; 

C1/C2 Asm 020502-N0902-08a 1 Stamp

1

D6 Piston Return Spring Seat w/seal; 

C1/C2 Asm 020502-N0902-08b 1 Debur

1

D6 Piston Return Spring Seat w/seal; 

C1/C2 Asm 020502-N0902-08c 1 Overmold

GENERAL COMPONENT INFORMATION

1

C1/C2 Asm 020502-N0902-08c 1 Overmold

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-08

eturn Spring Seat w/seal; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 2000 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 360 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator Stamp/Form, MLS, LMC 310 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator Stamp/Form, MLS, LMC 310 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.25

Parts/Layer: 1,152 

Number of Layers: 6

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.510 $0.65 $42.18 $125.10 $125.10 $0.33 $0.02 $0.06 $0.42 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.12 $0.35 $0.46 0.00% 0.00% 0.00% 0.00%

2 0.015 $1.32 $43.52 $125.10 $250.20 $0.02 $0.14 $0.81 $0.97 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

2 0.015 $1.32 $43.52 $125.10 $250.20 $0.02 $0.14 $0.81 $0.97 0.00% 0.00% 0.00% 0.00%

0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.35 $0.28 $1.22 $1.85 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.12 $0.11 $0.02

Base Cost Impact to Vehicle: $0.35 $0.28 $1.22 $1.85 $0.01 $0.12 $0.11 $0.02
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.001 $5,818 0.00% 4,500,000 60 5.00% $700 8 6912 6

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

able Packaging in Piece Cost: $0.01 $0.00 0 $10.00 7 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.012

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.42 $0.42 $0.33 $0.02 $0.06 $0.42 $0.00

0.00% $0.00 $0.46 $0.46 $0.00 $0.12 $0.35 $0.46 $0.00

0.00% $0.00 $0.97 $0.97 $0.02 $0.14 $0.81 $0.97 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

0.00% $0.00 $0.97 $0.97 $0.02 $0.14 $0.81 $0.97 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.35 $0.28 $1.22 $1.85 $0.00

Total 

Mark-up $1.85

$0.00 $1.85

14.00%

$0.26

$0.26 $2.10 $0 $0

Packaging Cost: $0.01

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $2.12

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium stamping press.

$0.00 $0.00 $0.00 $0.00 Tubling equipment with abrasive media.

$0.00 $0.00 $0.00 $0.00 Termoset heat press and rubber extrusion equipment operated in parallel.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Termoset heat press and rubber extrusion equipment operated in parallel.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$1.85

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tooling. 5 2 10 100 47 4700 96 37.60 85%

N/A 5 2 10 100 47 4700 96 37.60 85%

Multi-cavity tooling 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Multi-cavity tooling 5 2 10 100 47 4700 96 37.60 85%

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 2000 1.80 1.00

113 31.96 10 - 360 3,600 1.0 1.0 360 10.00 1.00 LD gives price per part

113 31.96 12 - 4 46 2.0 1.0 310 11.60 1.00 LD gives price per part

um Calculated Cycles Time Project Process Requirement

113 31.96 12 - 4 46 2.0 1.0 310 11.60 1.00 LD gives price per part

0 #DIV/0! - - 1 - 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


LD gives price per part

LD gives price per part
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Sealing Ring; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Sealing Ring; C1/C2 Asm 020585-N0902-02 1 Injection mold

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

GENERAL COMPONENT INFORMATION

1 0

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

1 0

Pallet Options

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

Investment $200 US funds (Mike S.)
Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020585-N0902-02

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 900 1 1

#### 1 1

Material Estimate + Actual Component Assembly Process)

GENERAL MANUFACTURING INFORMATION

#### 1 1

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.25

Parts/Layer: 1,152 

Number of Layers: 6

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.004 $1.74 $43.52 $100.01 $100.01 $0.01 $0.05 $0.11 $0.17 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

4

1,800,000

38,298

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.01 $0.05 $0.11 $0.17 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.01 $0.01 $0.00

Base Cost Impact to Vehicle: $0.01 $0.05 $0.11 $0.17 $0.00 $0.01 $0.01 $0.00
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.001 $23,271 0.00% 18,000,000 60 5.00% $700 33 6912 6

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

able Packaging in Piece Cost: $0.01 $0.00 0 $10.00 7 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.012

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Inject. Mold, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.17 $0.17 $0.01 $0.05 $0.11 $0.17 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.01 $0.05 $0.11 $0.17 $0.00

Total 

Mark-up $0.17

$0.00 $0.17

14.00%

$0.02

$0.02 $0.19 $0 $0

Packaging Cost: $0.01

Net Cost Impact to Vehicle: $0.20

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts) 229787

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium injection molding press.

$0.00 $0.00 $0.00 $0.00

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.17

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise otherwise there is a computation there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Four cavity tooling 5 2 10 100 47 4700 383 9.40 85%

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

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

451 7.99 4 - 4 16 1.0 1.0 900 4.00 1.00 LD give price per part

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


LD give price per part
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Center Bearing Sleeve; C1/C2 Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

0

0

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

1 D6 Center Bearing Sleeve; C1/C2 Asm 020590-N0902-05a 1 Forge

2 D6 Center Bearing Sleeve; C1/C2 Asm 020590-N0902-05b 1 Turn

0

GENERAL COMPONENT INFORMATION

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Cost per Tote: $75/Tote

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020590-N0902-05

earing Sleeve; C1/C2 Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Forge, MHC 240 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator CNC Turning, HC, PP, Base 144 1 1

#### 1 1

GENERAL MANUFACTURING INFORMATION

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 8x8x2

Parts/Layer: 30 

Number of Layers: 17

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.500 $0.65 $42.18 $150.09 $150.09 $0.33 $0.18 $0.63 $1.13 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $75.00 $75.00 $0.00 $0.26 $0.52 $0.78 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.33 $0.44 $1.15 $1.91 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 2.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.13 $0.15 $0.04

Base Cost Impact to Vehicle: $0.33 $0.44 $1.15 $1.91 $0.01 $0.13 $0.15 $0.04
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.020 $81,101 0.00% 4,500,000 60 5.00% $720 113 510 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.020

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Forge, LSHC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $1.13 $1.13 $0.33 $0.18 $0.63 $1.13 $0.00

0.00% $0.00 $0.78 $0.78 $0.00 $0.26 $0.52 $0.78 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.33 $0.44 $1.15 $1.91 $0.00

Total 

Mark-up $1.91

$0.00 $1.91

17.70%

$0.34

$0.34 $2.25 $0 $0

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $2.27

3

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Large forging press

$0.00 $0.00 $0.00 $0.00 Milling/turning cell with at least two stations, means for auto feed, part 

manipulation and transfer between stations.

$0.00 $0.00 $0.00 $0.00

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$1.91

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

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

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

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

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 15 - 1 15 1.0 1.0 240 15.00 1.00

113 31.96 50 - 1 25 1.0 1.0 144 25.00 1.00 Multi-station process

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Multi-station process
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Pusher Plate; Welded Hub Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 D6 C1/C2 Welded Hub Asm; C1/C2 Asm 020502-N0902-02 1

Assemble hubs, housings, 

paltes and spring together 

and weld together.

0

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

1 D6 Outer Clutch Hub; Welded Hub Asm 020502-N0902-03a 1 Stamp

GENERAL COMPONENT INFORMATION

1 D6 Outer Clutch Hub; Welded Hub Asm 020502-N0902-03a 1 Stamp

2 D6 Outer Clutch Hub; Welded Hub Asm 020502-N0902-03b 1 Spin Form

1 D6 Outer Clutch Hub; Welded Hub Asm 020502-N0902-03c 1 Grob form

1 D6 Outer Clutch Hub; Welded Hub Asm 020502-N0902-03d 1 Grob roll

1 D6 Outer Clutch Hub; Welded Hub Asm 020502-N0902-03e 1 Punch

1 D6 Pusher Plate; Welded Hub Asm 020502-N0902-04 1 Stamp

1 D6 Inner Clutch Hub; Welded Hub Asm 020502-N0902-05a 1 Stamp

1 D6 Inner Clutch Hub; Welded Hub Asm 020502-N0902-05b 1 Spin Form

1 D6 Inner Clutch Hub; Welded Hub Asm 020502-N0902-05c 1 Trim

1 D6 Inner Clutch Hub; Welded Hub Asm 020502-N0902-05d 1 Grob form

1

D6 Outer Clutch Hub Return Spring; 

Welded Hub Asm 020520-N0902-04a 1 Stamp

2

D6 Outer Clutch Hub Return Spring; 

Welded Hub Asm 020520-N0902-04b 1 Heat Treat

2 0
C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1

D6 Inner Clutch Hub Forging Upper; 

Welded Hub Asm 020502-N0902-06a 1 Manufactured

1

D6 Inner Clutch Hub Forging Lower; 

Welded Hub Asm 020502-N0902-07a 1 Manufactured

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-04

late; Welded Hub Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, MC 118 1 1

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1800 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1800 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 157 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 133 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 277 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 240 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 3789 1 2

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1895 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator CNC Milling, SMS, LC 157 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator Grinding, SMS, MHC 295 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator Grinding, SMS, MHC 161 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC 1895 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 280 1 1

#### 1 1
Material Estimate + Actual Component Assembly Process)

#### 1 1

SAC

SAC

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

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

OEM for Final or Sub-Assembly. In addition component material cost is accounted for 

in T1 quote sheet. Thus component cost will only be included for Mark-up 

Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 10x10x6

Parts/Layer: 80 

Number of Layers: 2

et size as Option #1. (Mike S. 020909)

Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 10x10x6

Parts/Layer: 80 

Number of Layers: 2

et size as Option #1. (Mike S. 020909)
PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $44.96 $125.19 $125.19 $0.00 $0.38 $1.06 $1.44 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 5.980 $0.65 $42.18 $125.10 $125.10 $3.89 $0.02 $0.07 $3.98 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 5.980 $0.65 $42.18 $125.10 $125.10 $3.89 $0.02 $0.07 $3.98 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.27 $0.80 $1.07 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.32 $0.94 $1.25 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.15 $0.45 $0.60 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.18 $0.52 $0.70 0.00% 0.00% 0.00% 0.00%

1 1.303 $0.65 $42.18 $125.10 $250.20 $0.85 $0.01 $0.07 $0.92 0.00% 0.00% 0.00% 0.00%

1 2.180 $0.65 $42.18 $125.10 $125.10 $1.42 $0.02 $0.07 $1.51 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $100.00 $100.00 $0.00 $0.24 $0.64 $0.88 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $20.00 $20.00 $0.00 $0.13 $0.07 $0.20 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $20.00 $20.00 $0.00 $0.23 $0.12 $0.36 0.00% 0.00% 0.00% 0.00%

1 1.160 $0.65 $42.18 $125.10 $125.10 $0.75 $0.02 $0.07 $0.84 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.17 $0.36 $0.52 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $11.65 $2.14 $5.23 $19.02 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: (8.80) ----- ----- ----- $0.10 $1.24 $1.14 $0.19

Base Cost Impact to Vehicle: $2.85 $2.14 $5.23 $10.22 $0.10 $1.24 $1.14 $0.19

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

ULATIONS: 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.018 $71,809 0.00% 4,500,000 60 5.00% $200 359 160 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.018

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $1.44 $1.44 $0.00 $0.38 $1.06 $1.44 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $3.98 $3.98 $3.89 $0.02 $0.07 $3.98 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

0.00% $0.00 $3.98 $3.98 $3.89 $0.02 $0.07 $3.98 $0.00

0.00% $0.00 $1.07 $1.07 $0.00 $0.27 $0.80 $1.07 $0.00

0.00% $0.00 $1.25 $1.25 $0.00 $0.32 $0.94 $1.25 $0.00

0.00% $0.00 $0.60 $0.60 $0.00 $0.15 $0.45 $0.60 $0.00

0.00% $0.00 $0.70 $0.70 $0.00 $0.18 $0.52 $0.70 $0.00

0.00% $0.00 $0.92 $0.92 $0.85 $0.01 $0.07 $0.92 $0.00

0.00% $0.00 $1.51 $1.51 $1.42 $0.02 $0.07 $1.51 $0.00

0.00% $0.00 $0.88 $0.88 $0.00 $0.24 $0.64 $0.88 $0.00

0.00% $0.00 $0.20 $0.20 $0.00 $0.13 $0.07 $0.20 $0.00

0.00% $0.00 $0.36 $0.36 $0.00 $0.23 $0.12 $0.36 $0.00

0.00% $0.00 $0.84 $0.84 $0.75 $0.02 $0.07 $0.84 $0.00

0.00% $0.00 $0.52 $0.52 $0.00 $0.17 $0.36 $0.52 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00
#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$4.74 $4.74 $0.00 $4.74 $4.74 $4.74

$4.05 $4.05 $0.00 $4.05 $4.05 $4.05

Material Labor Burden TMC Scrape

$11.65 $2.14 $5.23 $19.02 $0.00

Total 

Mark-up $19.02

$0.00 $19.02

14.00%

$2.66

$2.66 $12.88 $0 $0

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $12.90

Supplier, Customer and Intransit Inventory

Requirements (Parts)

3

Notes: 

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

3

1

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.
31

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.
SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

Assembly cell with two stations; one for manual assembly of components and 

one for automated compression and welding; use turn table to move assemblies 

through the process.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium to Large stamping press

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Medium to Large stamping press

$0.00 $0.00 $0.00 $0.00 Spin forming machine with means for auto feed and transfer between stations.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least three stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00 Manually operated Grob machine for ring groove.

$0.00 $0.00 $0.00 $0.00 Medium punch press machine cell.

$0.00 $0.00 $0.00 $0.00 Medium to Large stamping press

$0.00 $0.00 $0.00 $0.00 Medium to Large stamping press.

$0.00 $0.00 $0.00 $0.00 Spin forming machine with means for auto feed and transfer between stations.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least three stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least three stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00 Medium to Large stamping press

$0.00 $0.00 $0.00 $0.00 Heat treat cell with means for induction heating and austemping in molten salt 

bath.

$0.00 $0.00 $0.00 $0.00
$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$19.02

2

alue otherwise there is a computation error.

2

2

ue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.
Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Custom fixtures. 5 2 10 100 47 4700 96 37.60 85%

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

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Tools and Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Tools and Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

N/A 5 2 10 100 47 4700 96 37.60 85%

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

Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 61 - 1 31 1.0 1.0 118 30.50 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 1800 2.00 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 2 - 1 2 1.0 1.0 1800 2.00 1.00

113 31.96 23 - 1 23 1.0 1.0 157 23.00 1.00

113 31.96 27 - 1 27 1.0 1.0 133 27.00 1.00

113 31.96 13 - 1 13 1.0 1.0 277 13.00 1.00

113 31.96 15 - 1 15 1.0 1.0 240 15.00 1.00

113 31.96 2 - 1 2 1.0 2.0 3789 0.95 1.00

113 31.96 2 - 1 2 1.0 1.0 1895 1.90 1.00

113 31.96 23 - 1 23 1.0 1.0 157 23.00 1.00

113 31.96 12 - 1 12 1.0 1.0 295 12.20 1.00

113 31.96 22 - 1 22 1.0 1.0 161 22.40 1.00

113 31.96 2 - 1 2 1.0 1.0 1895 1.90 1.00

113 31.96 - - 280 3,600 1.0 1.0 280 12.86 1.00 Process not mapped by LD.

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00
0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

Process not mapped by LD.
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Inner Clutch Hub Forging Upper; Welded Hub Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1

D6 Inner Clutch Hub Forging Upper; 

Welded Hub Asm 020502-N0902-06a 1 Forge

1

D6 Inner Clutch Hub Forging Upper; 

Welded Hub Asm 020502-N0902-06b 1 Machining

1

D6 Inner Clutch Hub Forging Upper; 

Welded Hub Asm 020502-N0902-06c 1 Hone/burnish

GENERAL COMPONENT INFORMATION

1 Welded Hub Asm 020502-N0902-06c 1 Hone/burnish

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Cost per Tote: $75/Tote

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-06

tch Hub Forging Upper; Welded Hub Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorForge, MHC 212 2 2

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator CNC Milling, SMS, LC 129 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator Grinding, SMS, MHC 327 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Lathe/Turning Operator Grinding, SMS, MHC 327 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 1

Part Size: 8x8x4

Parts/Layer: 240 

Number of Layers: 2

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 1.480 $0.65 $42.18 $150.09 $300.18 $0.96 $0.40 $1.42 $2.78 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $100.00 $100.00 $0.00 $0.29 $0.78 $1.07 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $20.00 $20.00 $0.00 $0.11 $0.06 $0.18 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 $0.00 $37.60 $20.00 $20.00 $0.00 $0.11 $0.06 $0.18 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.96 $0.81 $2.26 $4.02 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 2.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.28 $0.32 $0.08

Base Cost Impact to Vehicle: $0.96 $0.81 $2.26 $4.02 $0.03 $0.28 $0.32 $0.08
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.005 $21,543 0.00% 4,500,000 60 5.00% $180 120 480 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.005

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Forge, LSHC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $2.78 $2.78 $0.96 $0.40 $1.42 $2.78 $0.00

0.00% $0.00 $1.07 $1.07 $0.00 $0.29 $0.78 $1.07 $0.00

0.00% $0.00 $0.18 $0.18 $0.00 $0.11 $0.06 $0.18 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

0.00% $0.00 $0.18 $0.18 $0.00 $0.11 $0.06 $0.18 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.96 $0.81 $2.26 $4.02 $0.00

Total 

Mark-up $4.02

$0.00 $4.02

17.70%

$0.71

$0.71 $4.74 $0 $0

Packaging Cost: $0.01

Net Cost Impact to Vehicle: $4.74

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium forge press.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least two stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least three stations, means for auto feed and transfer 

between stations.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 between stations.

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$4.02

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 34 - 1 34 1.0 2.0 212 17.00 2.00

113 31.96 56 - 1 28 1.0 1.0 129 28.00 1.00 Assumes parallel operations

113 31.96 11 - 1 11 1.0 1.0 327 11.00 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 11 - 1 11 1.0 1.0 327 11.00 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Assumes parallel operations
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: 05 LAUNCH CLUTCHES: Torque Converter

Component Quote Level: D6 Inner Clutch Hub Casting Lower; Welded Hub Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1

D6 Inner Clutch Hub Forging Lower; 

Welded Hub Asm 020502-N0902-07a 1 Forge

1

D6 Inner Clutch Hub Forging Lower; 

Welded Hub Asm 020502-N0902-07b 1 Machining

1

D6 Inner Clutch Hub Forging Lower; 

Welded Hub Asm 020502-N0902-07c 1 Hone/burnish

GENERAL COMPONENT INFORMATION

1 Welded Hub Asm 020502-N0902-07c 1 Hone/burnish

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Cost per Tote: $75/Tote

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

 CLUTCHES: Torque Converter Part Number: 020502-N0902-07

tch Hub Casting Lower; Welded Hub Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorForge, MHC 212 2 2

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator CNC Milling, SMS, LC 131 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Lathe/Turning Operator Grinding, SMS, MHC 327 1 1

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Lathe/Turning Operator Grinding, SMS, MHC 327 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 1

Part Size: 8x8x4

Parts/Layer: 240 

Number of Layers: 2

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.610 $0.65 $42.18 $150.09 $300.18 $0.40 $0.40 $1.42 $2.21 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $100.00 $100.00 $0.00 $0.29 $0.76 $1.05 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $37.60 $20.00 $20.00 $0.00 $0.11 $0.06 $0.18 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $37.60 $20.00 $20.00 $0.00 $0.11 $0.06 $0.18 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.40 $0.80 $2.24 $3.44 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 2.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.24 $0.28 $0.07

Base Cost Impact to Vehicle: $0.40 $0.80 $2.24 $3.44 $0.02 $0.24 $0.28 $0.07
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.005 $21,543 0.00% 4,500,000 60 5.00% $180 120 480 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.005

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Forge, LSHC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $2.21 $2.21 $0.40 $0.40 $1.42 $2.21 $0.00

0.00% $0.00 $1.05 $1.05 $0.00 $0.29 $0.76 $1.05 $0.00

0.00% $0.00 $0.18 $0.18 $0.00 $0.11 $0.06 $0.18 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $0.18 $0.18 $0.00 $0.11 $0.06 $0.18 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.40 $0.80 $2.24 $3.44 $0.00

Total 

Mark-up $3.44

$0.00 $3.44

17.70%

$0.61

$0.61 $4.05 $0 $0

Packaging Cost: $0.01

Net Cost Impact to Vehicle: $4.05

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium forge press.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least two stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00 Machining cell with at least three stations, means for auto feed and transfer 

between stations.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 between stations.

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$3.44

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 34 - 1 34 1.0 2.0 212 17.00 2.00

113 31.96 55 - 1 28 1.0 1.0 131 27.50 1.00 Assumes parallel operations

113 31.96 11 - 1 11 1.0 1.0 327 11.00 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 11 - 1 11 1.0 1.0 327 11.00 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Assumes parallel operations
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Pressure Plate

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Pressure Plate 020503-N0902-02a 1 Casting

GENERAL COMPONENT INFORMATION

1 Pressure Plate 020503-N0902-02a 1 Machining

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020503-N0902-02

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Malleable Cast Iron Mold/Cast/Sinter Operator Perm. Cast, LMC 128 3 3

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Lathe/Turning Operator Rot./Lin. Trans. Machining Line, IP 132 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 12x12x2

Parts/Layer: 16 

Number of Layers: 6

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 7.430 $0.41 $43.52 $100.06 $300.18 $3.05 $1.02 $2.35 $6.42 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 $0.00 $37.60 $175.00 $175.00 $0.00 $0.29 $1.33 $1.61 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $3.05 $1.31 $3.68 $8.03 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 5.00% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.40 $0.52 $0.48 $0.08

Base Cost Impact to Vehicle: $3.05 $1.31 $3.68 $8.03 $0.40 $0.52 $0.48 $0.08
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.057 $227,394 0.00% 4,500,000 60 5.00% $380 598 96 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.057

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Perm. Cast, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $6.42 $6.42 $3.05 $1.02 $2.35 $6.42 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

0.00% $0.00 $1.61 $1.61 $0.00 $0.29 $1.33 $1.61 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$3.05 $1.31 $3.68 $8.03 $0.00

Total 

Mark-up $8.03

$0.00 $8.03

18.50%

$1.49

$1.49 $9.52 $0 $0

Packaging Cost: $0.06

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $9.57

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Permanent mold gravity casting.

Machining cell with at least three stations, means for auto feed and transfer 

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Machining cell with at least three stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$8.03

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Custom Fixtures 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 85 - 1 85 1.0 3.0 128 28.17 3.00

um Calculated Cycles Time Project Process Requirement

113 31.96 82 - 1 27 1.0 1.0 132 27.33 1.00 Assumes parallel operations

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Assumes parallel operations
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Thrust Ring Retainer; DMFW Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Thrust Ring Retainer; DMFW Asm 020515-N0902-01a 1 Stamp

0

GENERAL COMPONENT INFORMATION

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Cost per Tote: $75/Tote

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-01

Retainer; DMFW Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Mold/Cast/Sinter Operator Perm. Cast, LMC 1565 1 1

#### 1 1

GENERAL MANUFACTURING INFORMATION

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 3x3x0.5

Parts/Layer: 4608

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.054 $0.74 $43.52 $100.06 $100.06 $0.04 $0.03 $0.06 $0.13 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.04 $0.03 $0.06 $0.13 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.01 $0.01 $0.00

Base Cost Impact to Vehicle: $0.04 $0.03 $0.06 $0.13 $0.00 $0.01 $0.01 $0.00
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.002 $7,792 0.00% 4,500,000 60 5.00% $2,500 3 18432 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.002

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, SSLC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.13 $0.13 $0.04 $0.03 $0.06 $0.13 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.04 $0.03 $0.06 $0.13 $0.00

Total 

Mark-up $0.13

$0.00 $0.13

10.30%

$0.01

$0.01 $0.15 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.15

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Small to medium stapming press with means for auto straighten.

$0.00 $0.00 $0.00 $0.00 Small to medium injection molding press; verticle.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Small to medium injection molding press; verticle.

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.13

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom Tooling 5 2 10 100 47 4700 96 37.60 85%

Custom Tooling 5 2 10 100 47 4700 0 #DIV/0! 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

Custom Tooling 5 2 10 100 47 4700 0 #DIV/0! 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 1565 2.30 1.00 Raw stock is roll sheet stock with p

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Raw stock is roll sheet stock with paper lamination.
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Thrust Bearing; DMFW Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Thrust Bearing; DMFW Asm 020590-N0902-01 1 Injection Mold

0

GENERAL COMPONENT INFORMATION

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Cost per Tote: $75/Tote

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020590-N0902-01

ng; DMFW Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Perm. Cast, LMC 2400 1 1

#### 1 1

GENERAL MANUFACTURING INFORMATION

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 3x3x0.5

Parts/Layer: 4608

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.005 $1.74 $43.52 $100.06 $100.06 $0.01 $0.02 $0.04 $0.07 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.01 $0.02 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00%

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

Base Cost Impact to Vehicle: $0.01 $0.02 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00
Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.002 $7,792 0.00% 4,500,000 60 5.00% $2,500 3 18432 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.002

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Inject. Mold, SSLC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.07 $0.07 $0.01 $0.02 $0.04 $0.07 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.01 $0.02 $0.04 $0.07 $0.00

Total 

Mark-up $0.07

$0.00 $0.07

10.30%

$0.01

$0.01 $0.08 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.08

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Small to medium injection molding press

$0.00 $0.00 $0.00 $0.00

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.07

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

20 cavity custom tool. 5 2 10 100 47 4700 96 37.60 85%

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 20 30 1.0 1.0 2400 1.50 1.00

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00



Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Fly Weel (stamped); Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Fly Weel (stamped); Fly Wheel Asm 020503-N0902-04a 1 Stamped

GENERAL COMPONENT INFORMATION

Fly Weel (stamped); Fly Wheel Asm 020503-N0902-04b 1 Machine

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020503-N0902-04

amped); Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 271 1 1

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Lathe/Turning Operator Rot./Lin. Trans. Machining Line, IP 132 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 12X12x2

Parts/Layer: 12

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 11.940 $0.74 $42.18 $125.10 $125.10 $8.84 $0.16 $0.46 $9.45 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $37.60 $175.00 $175.00 $0.00 $0.29 $1.33 $1.61 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $8.84 $0.44 $1.79 $11.07 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.06 $0.72 $0.66 $0.11

Base Cost Impact to Vehicle: $8.84 $0.44 $1.79 $11.07 $0.06 $0.72 $0.66 $0.11
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.090 $359,043 0.00% 4,500,000 60 5.00% $300 1197 48 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.090

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $9.45 $9.45 $8.84 $0.16 $0.46 $9.45 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $1.61 $1.61 $0.00 $0.29 $1.33 $1.61 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$8.84 $0.44 $1.79 $11.07 $0.00

Total 

Mark-up $11.07

$0.00 $11.07

14.00%

$1.55

$1.55 $12.62 $0 $0

Packaging Cost: $0.09

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $12.71

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Large stamping press.

Machining cell with at least three stations, means for auto feed and transfer 

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Machining cell with at least three stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$11.07

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 13 - 1 13 1.0 1.0 271 13.30 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 82 - 1 27 1.0 1.0 132 27.33 1.00 Multi station machining cell

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Multi station machining cell
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Starter Ring Gear; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Starter Ring Gear; Fly Wheel Asm 020503-N0902-05a 1 Forge and trim

GENERAL COMPONENT INFORMATION

Starter Ring Gear; Fly Wheel Asm 020503-N0902-05b 1 Machine

Starter Ring Gear; Fly Wheel Asm 020503-N0902-05c 1 Broach

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base
Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020503-N0902-05

Gear; Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. A-Steel-4140, Bar Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 120 2 2

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Lathe/Turning Operator Rot./Lin. Trans. Machining Line, IP 144 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 195 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 12X12x2

Parts/Layer: 12

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 1.810 $0.78 $42.18 $125.10 $250.20 $1.41 $0.70 $2.09 $4.20 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 $0.00 $37.60 $175.00 $175.00 $0.00 $0.26 $1.22 $1.48 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.22 $0.64 $0.86 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $1.41 $1.18 $3.94 $6.54 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.42 $0.39 $0.07

Base Cost Impact to Vehicle: $1.41 $1.18 $3.94 $6.54 $0.03 $0.42 $0.39 $0.07
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.090 $359,043 0.00% 4,500,000 60 5.00% $300 1197 48 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.090

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Forge, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $4.20 $4.20 $1.41 $0.70 $2.09 $4.20 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

0.00% $0.00 $1.48 $1.48 $0.00 $0.26 $1.22 $1.48 $0.00

0.00% $0.00 $0.86 $0.86 $0.00 $0.22 $0.64 $0.86 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$1.41 $1.18 $3.94 $6.54 $0.00

Total 

Mark-up $6.54

$0.00 $6.54

14.00%

$0.92

$0.92 $7.45 $0 $0

3

1

Notes: 

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

3

1
Packaging Cost: $0.09

Net Cost Impact to Vehicle: $7.54

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Large stamping press.

Machining cell with at least two stations, means for auto feed and transfer 

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Machining cell with at least two stations, means for auto feed and transfer 

between stations.

$0.00 $0.00 $0.00 $0.00 Medium Broach machine

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$6.54

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Custom fixtures 5 2 10 100 47 4700 96 37.60 85%

Custom fixtures 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 60 - 1 60 1.0 2.0 120 30.00 2.00

um Calculated Cycles Time Project Process Requirement

113 31.96 50 - 1 25 1.0 1.0 144 25.00 1.00 Multi-station machining cell

113 31.96 19 - 1 19 1.0 1.0 195 18.50 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Multi-station machining cell
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Spring Retainer; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Spring Retainer; Fly Wheel Asm 020515-N0902-02a 1 Roll form

GENERAL COMPONENT INFORMATION

Spring Retainer; Fly Wheel Asm 020515-N0902-02b 1 Heat treat

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-02

ner; Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 1200 1 1

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 240 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 12x6x1

Parts/Layer: 1536

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.190 $0.65 $42.18 $125.10 $125.10 $0.12 $0.04 $0.10 $0.26 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.42 $0.61 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.12 $0.23 $0.52 $0.87 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.06 $0.05 $0.01

Base Cost Impact to Vehicle: $0.12 $0.23 $0.52 $0.87 $0.00 $0.06 $0.05 $0.01
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.006 $23,375 0.00% 4,500,000 60 5.00% $2,500 9 6144 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.006

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.26 $0.26 $0.12 $0.04 $0.10 $0.26 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $0.61 $0.61 $0.00 $0.19 $0.42 $0.61 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.12 $0.23 $0.52 $0.87 $0.00

Total 

Mark-up $0.87

$0.00 $0.87

14.00%

$0.12

$0.12 $1.00 $0 $0

Packaging Cost: $0.01

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $1.00

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium roll forming machine

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Medium to large oven

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.87

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

N/A 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 3 - 1 3 1.0 1.0 1200 3.00 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 15 - 2,260 33,900 1.0 1.0 240 15.00 1.00 Daily production performed in a 9.5 

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Daily production performed in a 9.5 hour batch process.
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Spring Washer; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Spring Washer; Fly Wheel Asm 020515-N0902-03a 1 Stamp

GENERAL COMPONENT INFORMATION

Spring Washer; Fly Wheel Asm 020515-N0902-03b 1 Heat treat

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-03

er; Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 1500 1 1

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 240 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 3x3x0.5

Parts/Layer: 4608

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.374 $0.65 $42.18 $125.10 $125.10 $0.24 $0.03 $0.08 $0.35 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.42 $0.61 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.24 $0.22 $0.50 $0.97 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.06 $0.06 $0.01

Base Cost Impact to Vehicle: $0.24 $0.22 $0.50 $0.97 $0.00 $0.06 $0.06 $0.01
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.002 $7,792 0.00% 4,500,000 60 5.00% $2,500 3 18432 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.002

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.35 $0.35 $0.24 $0.03 $0.08 $0.35 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

0.00% $0.00 $0.61 $0.61 $0.00 $0.19 $0.42 $0.61 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.24 $0.22 $0.50 $0.97 $0.00

Total 

Mark-up $0.97

$0.00 $0.97

14.00%

$0.14

$0.14 $1.10 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $1.10

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Small to medium stapming press with means for auto straighten.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 Medium to large oven

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.97

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

N/A 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 1500 2.40 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 15 - 2,260 33,900 1.0 1.0 240 15.00 1.00 Daily production performed in a 9.5 

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Daily production performed in a 9.5 hour batch process.
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Spring Stop; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Spring Stop; Fly Wheel Asm 020515-N0902-04a 1 Stamp

GENERAL COMPONENT INFORMATION

Spring Stop; Fly Wheel Asm 020515-N0902-04b 1 Heat treat

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-04

 Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 973 1 1

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 240 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x10x0.5

Parts/Layer: 576

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.374 $0.65 $42.18 $125.10 $125.10 $0.24 $0.04 $0.13 $0.42 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.42 $0.61 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.24 $0.24 $0.55 $1.03 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.07 $0.06 $0.01

Base Cost Impact to Vehicle: $0.24 $0.24 $0.55 $1.03 $0.01 $0.07 $0.06 $0.01
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.016 $62,334 0.00% 4,500,000 60 5.00% $2,500 25 2304 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.016

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.42 $0.42 $0.24 $0.04 $0.13 $0.42 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $0.61 $0.61 $0.00 $0.19 $0.42 $0.61 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.24 $0.24 $0.55 $1.03 $0.00

Total 

Mark-up $1.03

$0.00 $1.03

14.00%

$0.14

$0.14 $1.17 $0 $0

Packaging Cost: $0.02

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $1.18

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Small to medium stapming press with means for auto straighten.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Medium to large oven

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$1.03

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

N/A 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 4 - 1 4 1.0 1.0 973 3.70 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 15 - 2,260 33,900 1.0 1.0 240 15.00 1.00 Daily production performed in a 9.5 

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Daily production performed in a 9.5 hour batch process.
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Spring Stop Cover; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Spring Stop Cover; Fly Wheel Asm 020515-N0902-05a 1 Stamp

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

GENERAL COMPONENT INFORMATION

C

1 0

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

1 0

Pallet Options
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30
Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-05

Cover; Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 1565 1 1

Material Estimate + Actual Component Assembly Process)

GENERAL MANUFACTURING INFORMATION

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.1

Parts/Layer: 2880

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.210 $0.45 $42.18 $125.10 $125.10 $0.09 $0.03 $0.08 $0.20 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.09 $0.03 $0.08 $0.20 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.01 $0.01 $0.00

Base Cost Impact to Vehicle: $0.09 $0.03 $0.08 $0.20 $0.00 $0.01 $0.01 $0.00
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.003 $12,467 0.00% 4,500,000 60 5.00% $2,500 5 11520 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.003

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.20 $0.20 $0.09 $0.03 $0.08 $0.20 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.09 $0.03 $0.08 $0.20 $0.00

Total 

Mark-up $0.20

$0.00 $0.20

14.00%

$0.03

$0.03 $0.23 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.23

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Small to medium stapming press with means for auto straighten.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.20

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise otherwise there is a computation there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 1565 2.30 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00



Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Outer Cover Pan; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Outer Cover Pan; Fly Wheel Asm 020503-N0902-06a 1 Stamp

GENERAL COMPONENT INFORMATION

1 Outer Cover Pan; Fly Wheel Asm 020503-N0902-06b 1 Machine

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020503-N0902-06

 Pan; Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 379 1 1

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Lathe/Turning Operator Rot./Lin. Trans. Machining Line, IP 129 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.1

Parts/Layer: 2880

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 5.940 $0.74 $42.18 $125.10 $125.10 $4.40 $0.11 $0.33 $4.84 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $37.60 $175.00 $175.00 $0.00 $0.29 $1.36 $1.65 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $4.40 $0.40 $1.69 $6.49 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.42 $0.39 $0.06

Base Cost Impact to Vehicle: $4.40 $0.40 $1.69 $6.49 $0.03 $0.42 $0.39 $0.06
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.003 $12,467 0.00% 4,500,000 60 5.00% $2,500 5 11520 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.003

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $4.84 $4.84 $4.40 $0.11 $0.33 $4.84 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $1.65 $1.65 $0.00 $0.29 $1.36 $1.65 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$4.40 $0.40 $1.69 $6.49 $0.00

Total 

Mark-up $6.49

$0.00 $6.49

14.00%

$0.91

$0.91 $7.40 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $7.40

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium stapming press with means for auto straighten.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Machining cell with means for auto feed and transfer between stations.

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$6.49

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

Custom fixtures 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 10 - 1 10 1.0 1.0 379 9.50 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 28 - 1 28 1.0 1.0 129 28.00 1.00

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00



Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Steel Ring; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Steel Ring; Fly Wheel Asm 020515-N0902-06a 1 Stamp

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

GENERAL COMPONENT INFORMATION

C

1 0

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

1 0

Pallet Options
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30
Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-06

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 1500 1 1

Material Estimate + Actual Component Assembly Process)

GENERAL MANUFACTURING INFORMATION

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.5

Parts/Layer: 576

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.615 $0.74 $42.18 $125.10 $125.10 $0.46 $0.03 $0.08 $0.57 0.00% 0.00% 0.00% 0.00%

9,574

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

47

450,000

1

450,000

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.46 $0.03 $0.08 $0.57 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.04 $0.03 $0.01

Base Cost Impact to Vehicle: $0.46 $0.03 $0.08 $0.57 $0.00 $0.04 $0.03 $0.01
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.016 $62,334 0.00% 4,500,000 60 5.00% $2,500 25 2304 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.016

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.57 $0.57 $0.46 $0.03 $0.08 $0.57 $0.00

TOOLING & INVESTMENT Manufacturing Cost

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS

North America

North America

FOB Ship Point

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.46 $0.03 $0.08 $0.57 $0.00

Total 

Mark-up $0.57

$0.00 $0.57

14.00%

$0.08

$0.08 $0.65 $0 $0

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $0.66

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium stapming press with means for auto straighten.

Mark-up Cost Process Information

es with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.57

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise otherwise there is a computation there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 1500 2.40 1.00

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00



Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Plastic Ring Bearing; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Plastic Ring Bearing; Fly Wheel Asm 020590-N0902-02 1 Injection Mold

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

GENERAL COMPONENT INFORMATION

C

1 0

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

1 0

Pallet Options
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30
Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-06

Bearing; Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 480 1 1

Material Estimate + Actual Component Assembly Process)

GENERAL MANUFACTURING INFORMATION

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.5

Parts/Layer: 576

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)
ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.036 $1.74 $43.52 $100.01 $100.01 $0.06 $0.09 $0.21 $0.36 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.06 $0.09 $0.21 $0.36 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.02 $0.02 $0.00

Base Cost Impact to Vehicle: $0.06 $0.09 $0.21 $0.36 $0.00 $0.02 $0.02 $0.00
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.016 $62,334 0.00% 4,500,000 60 5.00% $2,500 25 2304 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.016

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Inject. Mold, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.36 $0.36 $0.06 $0.09 $0.21 $0.36 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.06 $0.09 $0.21 $0.36 $0.00

Total 

Mark-up $0.36

$0.00 $0.36

14.00%

$0.05

$0.05 $0.41 $0 $0

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $0.43

3

1

Notes: 

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

3

1
Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

3

1

Notes: 

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

3

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium injection molding machine

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$0.36

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise otherwise there is a computation there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 1 - 4 30 1.0 1.0 480 7.50 1.00 Challenge LD's process time

um Calculated Cycles Time Project Process Requirement

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Challenge LD's process time
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Ring Retainer; Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

T1 0

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

1 Ring Retainer; Fly Wheel Asm 020515-N0902-07a 1 Stamp

GENERAL COMPONENT INFORMATION

1 Ring Retainer; Fly Wheel Asm 020515-N0902-07b 1 Heat Treat

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 0
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad
Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020515-N0902-07

er; Fly Wheel Asm

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

##### 1 1

T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 1500 1 1

T1 Assembly, Mark-up Applied 

GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Cut/Punch/Forming OperatorStamp/Form, MLS, LMC 240 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.
Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

PACKAGING CALCULATIONS: 

Packaging Type: 3

Part Size: 8x8x0.5

Parts/Layer: 576

Number of Layers: 4

et size as Option #1. (Mike S. 020909)

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad
yers of 8 on single Pallet Base. 

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.757 $0.74 $42.18 $125.10 $125.10 $0.56 $0.03 $0.08 $0.67 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $42.18 $125.10 $125.10 $0.00 $0.18 $0.52 $0.70 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

T1 or OEM Total Manufacturing Cost: $0.56 $0.20 $0.60 $1.37 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 1.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.09 $0.08 $0.01

Base Cost Impact to Vehicle: $0.56 $0.20 $0.60 $1.37 $0.01 $0.09 $0.08 $0.01
Cost per 

Piece Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

k/Pallet Investment Amortization: $0.016 $62,334 0.00% 4,500,000 60 5.00% $2,500 25 2304 6

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

ndable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.016

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: T2/T3 Stamp/Form, MSMC

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

0.00% $0.00 $0.67 $0.67 $0.56 $0.03 $0.08 $0.67 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $0.70 $0.70 $0.00 $0.18 $0.52 $0.70 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrape

$0.56 $0.20 $0.60 $1.37 $0.00

Total 

Mark-up $1.37

$0.00 $1.37

14.00%

$0.19

$0.19 $1.56 $0 $0

Packaging Cost: $0.02

3

1

Notes: 

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

3

1
Net Cost Impact to Vehicle: $1.58

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1

Notes: 

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

1

Notes: 

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

3

1

Notes: 

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

SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 Medium stapming press with means for auto straighten.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Medium heat treat over

$0.00 $0.00 $0.00 $0.00

SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$1.37

2

alue otherwise there is a computation error.

2
2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

2

ue otherwise there is a computation error.

Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

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

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

Custom tools and fixtures 5 2 10 100 47 4700 96 37.60 85%

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00

113 31.96 2 - 1 2 1.0 1.0 1500 2.40 1.00

um Calculated Cycles Time Project Process Requirement

113 31.96 15 - 2,260 33,900 1.0 1.0 240 15.00 1.00 Daily production processed in a 9.5 

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


Daily production processed in a 9.5 hour batch
Technology Level: VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

Vehicle Class: 2007-2009 VW Sportswagen

Study Case#: N0902

System Description: VW 6 Speed Direct Shift Gearbox

Component Description: LAUNCH CLUTCHES: Torque Converter

Component Quote Level: Dual Mass Fly Wheel Asm

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

Primary Process 

Description

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

Dual Mass Fly Wheel Asm 020503-N0902-01 1

Assemble pressure plate, 

fly wheel asm, retaing and 

thrust bearing together.

Fly Weel Asm; DMFW Asm 020503-N0902-03 1

Assemble remaining 

components into a fly wheel 

sub-assembly.

GENERAL COMPONENT INFORMATION

Spring Asm; DMFW Asm 020520-N0902-01 1

Preassemble springs and 

retainers.

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

1 0

0

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component A

1 0

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

1 Rivet; DMFW Asm 020580-N0902-01 8 Commodity

1 Rivet Small; Fly Wheel Asm 020580-N0902-02 3 Commodity

1 Large Spring; Spring Asm 020520-N0902-02 2 Commodity

1 Small Spring; Spring Asm 020520-N0902-03 4 Commodity

1 Pressure Plate 020503-N0902-02a 1 Manufactured

1 Thrust Ring Retainer; DMFW Asm 020515-N0902-01a 1 Manufactured
1 Thrust Bearing; DMFW Asm 020590-N0902-01 1 Manufactured

1 Fly Weel (stamped); Fly Wheel Asm 020503-N0902-04a 1 Manufactured

1 Starter Ring Gear; Fly Wheel Asm 020503-N0902-05a 1 Manufactured

1 Spring Retainer; Fly Wheel Asm 020515-N0902-02a 1 Manufactured

1 Spring Washer; Fly Wheel Asm 020515-N0902-03a 1 Manufactured

1 Spring Stop; Fly Wheel Asm 020515-N0902-04a 1 Manufactured

1 Spring Stop Cover; Fly Wheel Asm 020515-N0902-05a 1 Manufactured

1 Outer Cover Pan; Fly Wheel Asm 020503-N0902-06a 1 Manufactured

1 Steel Ring; Fly Wheel Asm 020515-N0902-06a 1 Manufactured

1 Plastic Ring Bearing; Fly Wheel Asm 020590-N0902-02 1 Manufactured

1 Ring Retainer; Fly Wheel Asm 020515-N0902-07a 1 Manufactured

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per 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
Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Sam

Investment $20K for tool

Piece Price, Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(30

Package: 6 Layers of 8 on single Pallet Base.

Cost per Tote: $75/Tote
 DSG versus Toyota 6 Speed Auto Transmission

VW Sportswagen

(N = New, 08 = Technology Package, 02 = Vehicle Class )

 Direct Shift Gearbox

LUTCHES: Torque Converter Part Number: 020503-N0902-01

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 159 6 1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 128 7 1

GENERAL MANUFACTURING INFORMATION

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 240 1 1

#### 3 3

#### 1 1

Material Estimate + Actual Component Assembly Process)

#### 1 1

S

S

S

S

SAC

SAC
SAC

SAC

SAC

SAC

SAC

SAC

SAC

SAC

SAC

SAC

SAC

PACKAGING CALCULATIONS: 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 12x12x2

Parts/Layer: 16 

Number of Layers: 6

et size as Option #1. (Mike S. 020909)

Rack/Pallet Investment Amortization:

Expendable Packaging in Piece Cost:

Packaging Cost Total:

PACKAGING CALCULATIONS: 

Packaging Type: 2

Part Size: 12x12x2

Parts/Layer: 16 

Number of Layers: 6

et size as Option #1. (Mike S. 020909)
PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.

PACKAGING CALCULATIONS: 

22cm)x45"(114cm)x34"(86cm)

00 US funds (Mike S.)

c Returnables Last 5 Years

um Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

allet Base $100/Base

er Pad $40/Pad

ler Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

yers of 8 on single Pallet Base.
OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $3.15 $0.95 $4.09 0.00% 0.00% 0.00% 0.00%

1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $4.57 $1.18 $5.74 0.00% 0.00% 0.00% 0.00%

1

450,000

9,574

47

450,000

10

MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.35 $0.63 $0.97 0.00% 0.00% 0.00% 0.00%

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Material Labor Burden TMC Scrap SG&A Profit ED&T

T1 or OEM Total Manufacturing Cost: $37.50 $8.06 $2.75 $48.31 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00%

(SAC) &T1 or OEM Mark-Up Values: (30.86) ----- ----- ----- $0.00 $0.00 $0.00 $0.00

Base Cost Impact to Vehicle: $6.64 $8.06 $2.75 $17.45 $0.00 $0.00 $0.00 $0.00

Number of Parts per Pallet/

Supplier, Customer and In

ULATIONS: 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

allet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 6

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

able Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

ULATIONS: 

OEM Plant Location:

upplier Plant Location:

OEM/T1 Classification: not applicable

Shipping Method:

ackaging Specification: NA

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap

0.00% $0.00 $4.09 $4.09 $0.00 $3.15 $0.95 $4.09 $0.00

0.00% $0.00 $5.74 $5.74 $0.00 $4.57 $1.18 $5.74 $0.00

FOB Ship Point

North America

North America

Costs Broken Out Into Categories with Quantity per Assembly Taken 

ARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cost

0.00% $0.00 $0.97 $0.97 $0.00 $0.35 $0.63 $0.97 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

#N/A #N/A #N/A $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.00 $0.01 $0.00 $0.08 $0.08 $0.08

$0.00 $0.02 $0.00 $0.06 $0.06 $0.06

$0.00 $1.87 $0.00 $3.74 $3.74 $3.74

$0.00 $0.69 $0.00 $2.76 $2.76 $2.76

$1.91 $1.91 $0.00 $1.91 $1.91 $1.91

$0.14 $0.14 $0.00 $0.14 $0.14 $0.14
$0.08 $0.08 $0.00 $0.08 $0.08 $0.08

$9.80 $9.80 $0.00 $9.80 $9.80 $9.80

$7.30 $7.30 $0.00 $7.30 $7.30 $7.30

$0.97 $0.97 $0.00 $0.97 $0.97 $0.97

$1.07 $1.07 $0.00 $1.07 $1.07 $1.07

$1.15 $1.15 $0.00 $1.15 $1.15 $1.15

$0.23 $0.23 $0.00 $0.23 $0.23 $0.23

$5.92 $5.92 $0.00 $5.92 $5.92 $5.92

$0.51 $0.51 $0.00 $0.51 $0.51 $0.51

$0.41 $0.41 $0.00 $0.41 $0.41 $0.41

$1.37 $1.37 $0.00 $1.37 $1.37 $1.37

Material Labor Burden TMC Scrape

$37.50 $8.06 $2.75 $48.31 $0.00

Total 

Mark-up $48.31

$0.00 $48.31

0.00%

$0.00

$0.00 $17.45 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $17.45

Supplier, Customer and In3

1

Notes: 

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

3

1

Supplier, Customer and Intransit Inventory

Requirements (Parts)

57447

3

1
3

Notes: 

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

31

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.
SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions

$0.00 $0.00 $0.00 $0.00

Manual assembly line with at least six evenely balanced stations with means for 

part manipulation, transfer between stations and hand tools and lift assists as 

needed.

$0.00 $0.00 $0.00 $0.00

Manual assembly line with at least seven evenely balanced stations with means 

for part manipulation, transfer between stations and hand tools and lift assists as 

needed.

es with Quantity per Assembly Taken into Account

Mark-up Cost Process Information

$0.00 $0.00 $0.00 $0.00 Manual assembly station with hand tools and lift assists as needed.

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00
SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00

$48.31

2

alue otherwise there is a computation error.

2

2
ue otherwise there is a computation error.

2

ue otherwise there is a computation error.
Tooling/Fixturing and Gauge 

Assumptions

Days/W

eek

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Custom hand tools and fixtures. 5 2 10 100 47 4700 96 37.60 85%

Custom hand tools and fixtures. 5 2 10 100 47 4700 96 37.60 85%

MANUFACTURING ASSUMPTIONS

Projected Operating Pattern Minimum Calculated Cycles Time 

Custom hand tools and fixtures. 5 2 10 100 47 4700 96 37.60 85%

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

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

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


Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 31.96 241 - 1 23 1.0 1.0 159 22.67 6.00

113 31.96 198 - 1 28 1.0 1.0 128 28.20 7.00

LD assumes 15 seconds per rivet; 

can be fastened at once taking 105 

time. Also assume multi-station ass

um Calculated Cycles Time Project Process Requirement

113 31.96 15 - 1 15 1.0 1.0 240 15.00 1.00

0 #DIV/0! - - 1 - 1.0 3.0 #DIV/0! #DIV/0! 3.00

0 #DIV/0! - - 1 - 1.0 1.0 #DIV/0! #DIV/0! 1.00 Assumes parallel operations

0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! 1.00


LD assumes 15 seconds per rivet; FEV assumes all 8 rivets

can be fastened at once taking 105 seconds out of the process

time. Also assume multi-station assembly line.

Assumes parallel operations
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: 5 Speed Versus 6 Speed Transmission OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class) Components per Transmission: OEM/T1 Classification:

System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission Annual Component Volume: Shipping Method:

Component Description: Part Number: 02****-N0802-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

9,574

10

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

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

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

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: 5 Speed Versus 6 Speed Transmission OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class) Components per Transmission: OEM/T1 Classification:

System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission Annual Component Volume: Shipping Method:

Component Description: Part Number: 02****-N0802-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

9,574

10

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

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

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

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: 5 Speed Versus 6 Speed Transmission OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class) Components per Transmission: OEM/T1 Classification:

System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission Annual Component Volume: Shipping Method:

Component Description: Part Number: 02****-N0802-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

9,574

10

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

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

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly. 9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.00

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

Mark-up $0.00

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

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Supplier for Subassembly.

3

1

Notes: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 #N/A #N/A #N/A #N/A #N/A #N/A $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: #N/A

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: 5 Speed Versus 6 Speed Transmission OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class) Components per Transmission: OEM/T1 Classification:

System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission Annual Component Volume: Shipping Method:

Component Description: Part Number: 02****-N0802-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

9,574

10

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

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

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

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

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

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

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

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

Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

$0.00

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411