### 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 **LA UNCH CLUTCHES:** 

1 **01 Torque Converter Assembly** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)**ItemSubsystem



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

**Speed Wet DCT Analyis Conversion from DCT Application to** 

**Launch Clutch for IMGA Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup 

# NEW TECHNOLOGY PACKAGE COST INFORMATION
**6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)** **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)**ItemSubsystem



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

**Speed Wet DCT Analyis Conversion from DCT Application to** 

**Launch Clutch for IMGA Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup 

# NEW TECHNOLOGY PACKAGE COST INFORMATION
**6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)** **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)**ItemSubsystem



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

**Speed Wet DCT Analyis Conversion from DCT Application to** 

**Launch Clutch for IMGA Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup 

# NEW TECHNOLOGY PACKAGE COST INFORMATION
**6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)** **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)**ItemSubsystem



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

**Speed Wet DCT Analyis Conversion from DCT Application to** 

**Launch Clutch for IMGA Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup 

# NEW TECHNOLOGY PACKAGE COST INFORMATION
**6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)** **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 **Cy linder Blocks** 

A1 **01**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

B1 **02**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

C1 **03**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

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



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

E1 **65**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

F1 **66**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$** 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystem 

# BASE

**TECHNO**

**LOGY**

**Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM** MarkupSub-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)**ItemSubsystem



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

**Speed Wet DCT Analyis Conversion from DCT Application to** 

**Launch Clutch for IMGA Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup 

# NEW TECHNOLOGY PACKAGE COST INFORMATION
**6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)** **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 **Cy linder 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)**ItemSubsystemSub-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)**ItemSubsystem



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

**Speed Wet DCT Analyis Conversion from DCT Application to** 

**Launch Clutch for IMGA Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup 

# NEW TECHNOLOGY PACKAGE COST INFORMATION
**6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen (Max Torque Capacity 350N*m)** **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 **LA UNCH CLUTCHES:** 

1 **01**ItemSubsystem 

# 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
**6 Speed 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

DRAFTItemSubsystem 

# 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
**6 Speed 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

DRAFTItemSubsystem 

# 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
**6 Speed 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

DRAFTItemSubsystem 

# 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
**6 Speed 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 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2

E1 **65**

2

F1 **66**ItemSubsystem 

# 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

DRAFTItemSubsystem 

# 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
**6 Speed 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 **Cy linder Blocks** 

A1 **01**

B1 **02**ItemSubsystemSub-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

DRAFTItemSubsystem 

# 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
**6 Speed 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 Subsy **stem: Integrated Motor-Generator A ssembly**  **(IMGA )** 

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 1 **01 Torque Converter A**  **ssembly**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 2 **02 Clutch A**  **ssembly 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 W elded 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; W elded Hub Asm 02 05 02

- N0902

- 03 1 Full pia to 020502-N0902-02



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A3 D6 Pusher Plate; W elded Hub Asm 02 05 02

- N0902

- 04 1 Full pia to 020502-N0902-02



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A4 D6 Inner Clutch Hub; W elded Hub Asm 02 05 02

- N0902

- 05 1 Full pia to 020502-N0902-02



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### Part Number **Total**

**Packaging**

**Cost**

**(Component**

**/ A ssembly)**  **Net**

**Component/**

**As sembly** 

**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/**

**As sembly)** Subsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**SubassemblyComponentSub-Subsystem



### Investment

**(X1000) Tooling** 

**(x1000)** MarkupAssembly



### Name/Description 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**As sembly)**  

# 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; W elded

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; W elded

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 W heel 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 W eel Asm; DMFW Asm X 02 05 03

- N0902

- 03 1 Full pia to 020503-N0902-01



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### B1 Fly W eel (stamped); Fly W heel 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 X 02 05 03

- N0902

- 05 1 1.41 $ 1.18

$ 3.94

$ **6.54**

**$** 0.03

$ 0.42

$ 0.39

$ 0.07

$ **0.92**

**$** 0.09

$ **7.54**

**$** Starter Ring Gear; Fly W heel Asm Full 

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

**- $** 

**-**

**$**

**-**

**$**



### B3 Outer Cover Pan; Fly W heel 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**

**/ A ssembly)**  **Net**

**Component/**

**As sembly** 

**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/**

**As sembly)** Subsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**SubassemblyComponentSub-Subsystem



### Investment

**(X1000) Tooling** 

**(x1000)** MarkupAssembly



### Name/Description 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**As sembly)**  

# 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 W heel 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 W asher; Fly W heel 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 W heel 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 W heel 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 W heel 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 W heel 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 X 02 05 20

- N0902

- 03 4 Full pia to 020520-N0902-01



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$** 1.00

$ **1.00**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### Small Spring; Spring Asm pia to 020520-N0902-01 

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



### B D6 Outer Clutch Hub Return Spring; W elded

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 W heel 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 W heel 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 )**I T** **E M** **A S** **Y L** **V L**  

## QTY/

**P.T. L** **a b** **e l** **#**



## Qty



# 02 **TRA NSMISSION 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 Q** **T Y** **/ P** **. T** **. R** **o y** **a l** **t y** **M a** **t e** **r i** **a l** **/ F** **i n** **i s** **h (** **s )** **P e** **r f** **o r** **m a** **n c** **e C** **O M** **P O** **N E** **N T**  

### Default, indicates cost study required for identified item.**P a** **r t** **E x** **i s** **t e** **n c** **e S** **U B** **S Y** **S T** **E M** **S U** **B -** **S U** **B S** **Y S** **T E** **M A** **S S** **E M** **B L** **Y S** **U B** **A S** **S E** **M B** **L Y** **W e** **i g** **h t** **/ S** **i z** **e F** **u n** **c t** **i o** **n** 

## NAME/DECRIPTION **CHECK OFF ATTRIBUTES**

**WHICH ARE DIFFERENT**

**BETWEEN COMPARISON**

**TECHNOLOGY PACKAGES PART NUMBER** 

**Boltings**

**Sealing Elements**

**Bearing Elements**



# GENERA **L PA RT** 

**INFORMA**

**TION**

**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 W asher; 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, W asher; Output Shaft Asm

D6 W asher, 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; W elded Hub Asm D6 Inner Clutch Hub; W elded Hub Asm

D6 Inner Clutch Hub Casting Lower; W elded 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 W elded Hub Asm; C1/C2 Asm

D6 Outer Clutch Hub; W elded Hub Asm

D6 Pusher Plate; W elded 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 Th rust Ring Retainer; DMFW Asm 02 05 15

- N0902

- 01 1

B Spring Retainer; Fly W heel Asm 02 05 15

- N0902

- 02 1

C Spring W asher; Fly W heel Asm 02 05 15

- N0902

- 03 1

D Spring Stop; Fly W heel Asm 02 05 15

- N0902

- 04 1

E Spring Stop Cover; Fly W heel Asm 02 05 15

- N0902

- 05 1

F Steel Ring; Fly W heel Asm 02 05 15

- N0902

- 06 1

G Ring Retainer; Fly W heel 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 W heel 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 W heel Asm

Outer Cover Pan; Fly W heel Asm

**Pipes, Hoses, Ducting**

D6 Snap-Ring, Outer shell Pressure Plate; DMFW Asm Dual Mass Fly W heel Asm

Fly W eel Asm; DMFW Asm

D6 Outer Clutch Hub Return Spring; W elded 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 W eel (stamped); Fly W heel Asm

B Rivet Small; Fly W heel 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 W heel Asm Th rust 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**

**Sw itches**  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

**Sw itches**  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**

**Paw ls** 

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 Transmission** 



# Vehicle Class: **2007-2009 VW Sportswagen** 

# Study **Case#: N0902**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 W heel 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 Assembly Process)

**0**



# D 

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

1 D6 C1/C2 W elded 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. 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 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 Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020500-N0902-00**

OEM Assembly costs associated with launch controls

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

# PACKAGING **CALCULATIONS:**

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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



# Rack/Pallet 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**



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



# Packaging Cost Total: **$0.000** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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. 

# Costs Broken Out Into Categories 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**

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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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 Transmission** 



# Vehicle Class: **2007-2009 VW Sportswagen** 

# Study **Case#: N0902**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-29**

D6 C1 Cover w/overmold; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# 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: **$0.036** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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**

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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Project Process Requirement **Minimum Calculated Cycles Time**

**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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-26**

D6 Outer Shell Asm; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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



# Rack/Pallet 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**



# 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: **$0.036** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Forge, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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**

**MARK-UP COSTS TOTAL COSTS**  **Manufacturing Cost Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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

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

**2**



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern 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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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 Transmission** 



# Vehicle Class: **2007-2009 VW Sportswagen** 

# Study **Case#: N0902**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **05 LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: D6 C1 Hub Asm

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

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-23**

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

# 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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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



# Rack/Pallet 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**



# 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: **$0.036** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Forge, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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**

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

**2**



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Project Process Requirement **Minimum Calculated Cycles Time**

**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 dropped.

**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 Transmission** 



# Vehicle Class: **2007-2009 VW Sportswagen** 

# Study **Case#: N0902**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-20**

D6 Center Hub Asm; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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



# Rack/Pallet 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**



# 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: **$0.036** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Forge, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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**

**MARK-UP COSTS TOTAL COSTS**  **Manufacturing Cost Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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

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

**2**



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern 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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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. 

# Minimum 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 Transmission** 



# Vehicle Class: **2007-2009 VW Sportswagen** 

# Study **Case#: N0902**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-16**

D6 Inner Clutch Pack Asm; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**Expendable Packaging in Piece Cost:**

**Packaging Cost Total:**

# PACKAGING **CALCULATIONS:**

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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



# Rack/Pallet 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**



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

# PACKAGING **CALCULATIONS:**

**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: **$0.027**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Fine Blank, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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**

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

**2**



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Project Process Requirement **Minimum Calculated Cycles Time**

LD places too much time on sort and stack

**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 meet production volumes.

**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 Transmission** 



# Vehicle Class: **2007-2009 VW Sportswagen** 

# Study **Case#: N0902**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-12**

D6 Outer Clutch Pack Asm; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**Expendable Packaging in Piece Cost:**

**Packaging Cost Total:**

# PACKAGING **CALCULATIONS:**

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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



# Rack/Pallet 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**



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

# PACKAGING **CALCULATIONS:**

**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: **$0.027**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Fine Blank, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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. 

# Costs Broken Out Into Categories 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**

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

**2**



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 handling and stacking. 

# Minimum 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 meet production volumes.

**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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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 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 Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-11**

D6 Inner Clutch Thrust Surface; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS **1500 1**  **1**

**#### 1**  **1** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 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 Type: 3

Part Size: 8x8x0.25 Parts/Layer: 1,152 Number of Layers: 6 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# Expendable 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** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Inject. Mold, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



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

# SG&A **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-10**

D6 Piston w/seal; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **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 **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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 8x8x0.25 Parts/Layer: 1,152 Number of Layers: 6 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# Expendable 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** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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. 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

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. 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 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)

# 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-09**

D6 C1/C2 Spring Plate Asm; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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 Operator Stamp/Form, MLS, LMC **2000 1**  **1**

T1 Assembly, Mark-up Applied
@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC **400 1**  **1**

**#### 1**  **1** 

# GENERAL MANUFACTURING INFORMATION



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

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

# Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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



# Rack/Pallet 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**



# Expendable 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** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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**  

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-08**

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

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **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 **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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 8x8x0.25 Parts/Layer: 1,152 Number of Layers: 6 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# Expendable 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** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern 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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **05 LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Sealing Ring; C1/C2 Asm

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

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

# Primary Process

**Description**

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 Assembly Process)

**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. 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 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 Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020585-N0902-02**

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS **900 1**  **1**

**#### 1**  **1** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 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 Type: 3

Part Size: 8x8x0.25 Parts/Layer: 1,152 Number of Layers: 6 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# Expendable 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** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Inject. Mold, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



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

# SG&A **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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**  

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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 Assembly Process)

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. 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 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

# Cost per Tote: $75/Tote

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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020590-N0902-05**

D6 Center Bearing Sleeve; C1/C2 Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **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



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# 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: **$0.020** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Forge, LSHC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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**  

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **05 LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: D6 Pusher Plate; Welded Hub Asm

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

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

# Primary Process

**Description**

A 

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

T1 D6 C1/C2 W elded 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; W elded Hub Asm 020502-N0902-03a **1** Stamp



# GENERAL COMPONENT INFORMATION

1 D6 Outer Clutch Hub; W elded Hub Asm 020502-N0902-03a **1** Stamp

2 D6 Outer Clutch Hub; W elded Hub Asm 020502-N0902-03b **1** Spin Form

1 D6 Outer Clutch Hub; W elded Hub Asm 020502-N0902-03c **1** Grob form

1 D6 Outer Clutch Hub; W elded Hub Asm 020502-N0902-03d **1** Grob roll

1 D6 Outer Clutch Hub; W elded Hub Asm 020502-N0902-03e **1** Punch

1 D6 Pusher Plate; W elded Hub Asm 020502-N0902-04 **1** Stamp

1 D6 Inner Clutch Hub; W elded Hub Asm 020502-N0902-05a **1** Stamp

1 D6 Inner Clutch Hub; W elded Hub Asm 020502-N0902-05b **1** Spin Form

1 D6 Inner Clutch Hub; W elded Hub Asm 020502-N0902-05c **1** Trim

1 D6 Inner Clutch Hub; W elded Hub Asm 020502-N0902-05d **1** Grob form

1 D6 Outer Clutch Hub Return Spring;

We lded Hub Asm 020520-N0902-04a **1** Stamp

2 D6 Outer Clutch Hub Return Spring;

We lded 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 Assembly Process)

1 **0**



# D 

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

1 D6 Inner Clutch Hub Forging Upper;

We lded Hub Asm 020502-N0902-06a **1** Manufactured

1 D6 Inner Clutch Hub Forging Lower;

We lded 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. 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-04**

D6 Pusher Plate; Welded Hub Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# T1 Assembly, Mark-up Applied
@ Bottom. Not Applicable We lding/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**

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

# PACKAGING **CALCULATIONS:**

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

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

# PACKAGING **CALCULATIONS:**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



# Rack/Pallet 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**



# 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: **$0.018** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### 3



# Notes:

**a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.**  **3 1** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

**2**



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

**2**

### 2



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern 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%** **P c** **s .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



# 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 

# Minimum 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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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;

We lded Hub Asm 020502-N0902-06a **1** Forge

1 D6 Inner Clutch Hub Forging Upper;

We lded Hub Asm 020502-N0902-06b **1** Machining

1 D6 Inner Clutch Hub Forging Upper;

We lded Hub Asm 020502-N0902-06c **1** Hone/burnish



# GENERAL COMPONENT INFORMATION

1 We lded Hub Asm 020502-N0902-06c **1** Hone/burnish



# C 

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

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. 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 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

# Cost per Tote: $75/Tote

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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-06**

D6 Inner Clutch Hub Forging Upper; Welded Hub Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Forge, 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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 1

Part Size: 8x8x4 Parts/Layer: 240 Number of Layers: 2 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# 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: **$0.005** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Forge, LSHC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem 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 R** **e f** **e r** **e n** **c e** **#** 

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

# Primary Process

**Description**

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;

We lded Hub Asm 020502-N0902-07a **1** Forge

1 D6 Inner Clutch Hub Forging Lower;

We lded Hub Asm 020502-N0902-07b **1** Machining

1 D6 Inner Clutch Hub Forging Lower;

We lded Hub Asm 020502-N0902-07c **1** Hone/burnish



# GENERAL COMPONENT INFORMATION

1 We lded Hub Asm 020502-N0902-07c **1** Hone/burnish



# C 

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

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. 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 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

# Cost per Tote: $75/Tote

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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**05 LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020502-N0902-07**

D6 Inner Clutch Hub Casting Lower; Welded Hub Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# #### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Forge, 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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 1

Part Size: 8x8x4 Parts/Layer: 240 Number of Layers: 2 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# 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: **$0.005** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Forge, LSHC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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. 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Pressure Plate

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

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

# Primary Process

**Description**

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 Assembly Process)

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020503-N0902-02**

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 12x12x2 Parts/Layer: 16 Number of Layers: 6 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/Pallet 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**



# 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: **$0.057** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Perm. Cast, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



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

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

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Thrust Ring Retainer; DMFW Asm

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

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

# Primary Process

**Description**

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 Assembly Process)

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. 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 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

# Cost per Tote: $75/Tote

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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-01**

Thrust Ring Retainer; DMFW Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **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



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 3x3x0.5 Parts/Layer: 4608 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.002** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Stamp/Form, SSLC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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. 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 paper lamination.

**0 #DIV/0!** 

- - 1

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

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Thrust Bearing; DMFW Asm

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

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

# Primary Process

**Description**

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 Assembly Process)

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. 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 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

# Cost per Tote: $75/Tote

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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020590-N0902-01**

Thrust Bearing; DMFW Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **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



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 3x3x0.5 Parts/Layer: 4608 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.002** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Inject. Mold, SSLC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

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

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

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

**SG&A Profit**  **ED&T Mark-up** 

**Total**

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

**$0.07 2** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Fly Weel (stamped); Fly Wheel Asm

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

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

# Primary Process

**Description**

A 

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

T1 **0**



# B 

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

1 Fly W eel (stamped); Fly W heel Asm 020503-N0902-04a **1** Stamped



# GENERAL COMPONENT INFORMATION

Fly W eel (stamped); Fly W heel Asm 020503-N0902-04b **1** Machine



# C 

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

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020503-N0902-04**

Fly Weel (stamped); Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming Operator Stamp/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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 12X12x2 Parts/Layer: 12 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.090** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

**5 2**  **10 100**  **47 4700**  **96 37.60**  **85%**

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Starter Ring Gear; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020503-N0902-05a **1** Forge and trim



# GENERAL COMPONENT INFORMATION

Starter Ring Gear; Fly W heel Asm 020503-N0902-05b **1** Machine

Starter Ring Gear; Fly W heel Asm 020503-N0902-05c **1** Broach



# C 

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

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. 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) 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

# 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020503-N0902-05**

Starter Ring Gear; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. A-Steel-4140, Bar Cut/Punch/Forming Operator Stamp/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 Operator Stamp/Form, MLS, LMC **195 1**  **1**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 12X12x2 Parts/Layer: 12 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

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

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)

Piece Price, Pallet Base $100/Base

# Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.090** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Forge, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



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

Custom tools and fixtures **5 2**  **10 100**  **47 4700**  **96 37.60**  **85%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern 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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Spring Retainer; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020515-N0902-02a **1** Roll form



# GENERAL COMPONENT INFORMATION

Spring Retainer; Fly W heel Asm 020515-N0902-02b **1** Heat treat



# C 

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

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-02**

Spring Retainer; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 12x6x1 Parts/Layer: 1536 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.006** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

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

**$0.00 $0.00**  **$0.00 $0.00**  Medium roll forming machine 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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 hour batch process.

**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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Spring Washer; Fly Wheel Asm

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

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

# Primary Process

**Description**

A 

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

T1 **0**



# B 

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

1 Spring W asher; Fly W heel Asm 020515-N0902-03a **1** Stamp



# GENERAL COMPONENT INFORMATION

Spring W asher; Fly W heel Asm 020515-N0902-03b **1** Heat treat



# C 

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

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-03**

Spring Washer; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 3x3x0.5 Parts/Layer: 4608 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.002** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



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

Custom tools and fixtures **5 2**  **10 100**  **47 4700**  **96 37.60**  **85%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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 hour batch process.

**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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Spring Stop; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020515-N0902-04a **1** Stamp



# GENERAL COMPONENT INFORMATION

Spring Stop; Fly W heel Asm 020515-N0902-04b **1** Heat treat



# C 

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

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-04**

Spring Stop; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 8x10x0.5 Parts/Layer: 576 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.016** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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. 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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 hour batch process.

**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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Spring Stop Cover; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020515-N0902-05a **1** Stamp



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

**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. 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 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)

# 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-05**

Spring Stop Cover; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS, LMC **1565 1**  **1**



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

**#### 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: 3

Part Size: 8x8x0.1 Parts/Layer: 2880 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

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

# Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.003** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



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

Custom tools and fixtures **5 2**  **10 100**  **47 4700**  **96 37.60**  **85%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Outer Cover Pan; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020503-N0902-06a **1** Stamp



# GENERAL COMPONENT INFORMATION

1 Outer Cover Pan; Fly W heel Asm 020503-N0902-06b **1** Machine



# C 

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

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020503-N0902-06**

Outer Cover Pan; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming Operator Stamp/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**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 8x8x0.1 Parts/Layer: 2880 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.003** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

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

**$0.00 $0.00**  **$0.00 $0.00**  Medium stapming press with means for auto straighten. 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Steel Ring; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020515-N0902-06a **1** Stamp



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

**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. 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 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)

# 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-06**

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming Operator Stamp/Form, MLS, LMC **1500 1**  **1**



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

**#### 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: 3

Part Size: 8x8x0.5 Parts/Layer: 576 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

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

# Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.016** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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 Costs Broken Out Into Categories 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** 



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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



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

Custom tools and fixtures **5 2**  **10 100**  **47 4700**  **96 37.60**  **85%** 

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Plastic Ring Bearing; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020590-N0902-02 **1** Injection Mold



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

**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. 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 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)

# 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-06**

Plastic Ring Bearing; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS **480 1**  **1**



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

**#### 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: 3

Part Size: 8x8x0.5 Parts/Layer: 576 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

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

# Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.016** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **T2/T3 Inject. Mold, MSMC** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

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

**$0.00 $0.00**  **$0.00 $0.00**  Medium injection molding machine 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Ring Retainer; Fly Wheel Asm

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

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

# Primary Process

**Description**

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 W heel Asm 020515-N0902-07a **1** Stamp



# GENERAL COMPONENT INFORMATION

1 Ring Retainer; Fly W heel Asm 020515-N0902-07b **1** Heat Treat



# C 

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

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. 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. 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

# 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"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020515-N0902-07**

Ring Retainer; Fly Wheel Asm

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# ##### **1 1** 

T1 Assembly, Mark-up Applied
@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming Operator Stamp/Form, MLS, LMC **1500 1**  **1**

T1 Assembly, Mark-up Applied



# GENERAL MANUFACTURING INFORMATION

@ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, MLS, LMC **240 1**  **1**



# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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: 3

Part Size: 8x8x0.5 Parts/Layer: 576 Number of Layers: 4 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

**PACKAGING CALCULATIONS:** 

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)

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. **PACKAGING CALCULATIONS:** 

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)

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

# Package: 6 Layers of 8 on single Pallet 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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**1** 0.000 **#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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **)**



# Rack/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**



# 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: **$0.016** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

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

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**#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 into Account**

**MARK-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 S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

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

**$0.00 $0.00**  **$0.00 $0.00**  Medium stapming press with means for auto straighten. 

# Costs Broken Out Into Categories 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** 



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

### 2



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

**2** 

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

Custom tools and fixtures **5 2**  **10 100**  **47 4700**  **96 37.60**  **85%**

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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 

# Minimum 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 hour batch

**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**  

# Sy **stem Description: VW 6 Speed Direct Shift Gearbox**  

# Component Description: **LAUNCH CLUTCHES: Torque Converter**



# Component Quote Level: Dual Mass Fly Wheel Asm

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

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

# Primary Process

**Description**

A 

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

Dual Mass Fly W heel Asm 020503-N0902-01 **1** Assemble pressure plate,
fly wheel asm, retaing and

thrust bearing together.

Fly W eel 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 Assembly Process)

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 W heel 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 W eel (stamped); Fly W heel Asm 020503-N0902-04a **1** Manufactured

1 Starter Ring Gear; Fly W heel Asm 020503-N0902-05a **1** Manufactured

1 Spring Retainer; Fly W heel Asm 020515-N0902-02a **1** Manufactured

1 Spring W asher; Fly W heel Asm 020515-N0902-03a **1** Manufactured

1 Spring Stop; Fly W heel Asm 020515-N0902-04a **1** Manufactured

1 Spring Stop Cover; Fly W heel Asm 020515-N0902-05a **1** Manufactured

1 Outer Cover Pan; Fly W heel Asm 020503-N0902-06a **1** Manufactured

1 Steel Ring; Fly W heel Asm 020515-N0902-06a **1** Manufactured

1 Plastic Ring Bearing; Fly W heel Asm 020590-N0902-02 **1** Manufactured

1 Ring Retainer; Fly W heel 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. 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 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

# VW 6 Speed DSG versus Toyota 6 Speed Auto Transmission

**2007-2009 VW Sportswagen**

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

**VW 6 Speed Direct Shift Gearbox**

**LAUNCH CLUTCHES: Torque Converter** 

# Part Number: **020503-N0902-01**

**OEM/Supplier Classification Material** 
**Specification Labor** 

**Classification Burden** 

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



# 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** 

# Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw 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 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: 12x12x2 Parts/Layer: 16 Number of Layers: 6 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet 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 Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

# PACKAGING **CALCULATIONS:**

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)

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. **PACKAGING CALCULATIONS:** 

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)

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.

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:
Annual Engine Volume (CPV): Supplier Plant Location:
Components per Engine: OEM/T1 Classification:
Annual Component Volume: Shipping Method:

We ekly Component Volume: Packaging Specification:

Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

# Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

# End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB)**

**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 N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **** 

# PACKAGING **CALCULATIONS:**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



# Rack/Pallet 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**



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



# Packaging Cost Total: **$0.000** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:
Supplier Plant Location:

OEM/T1 Classification: **not applicable** 

# Shipping Method: Packaging Specification: **NA**

**Total**

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

# End Item
**Scrap**

**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 into Account**

**MARK-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** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **** 

### 3 **1**



# Notes:

**a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.**  **3 1** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



# 57447

**3 1** 

### 3 

# 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&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

# Process & Equipment Assumptions

**$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. 

# Costs Broken Out Into Categories 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** 



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

**2**

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

**2**



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

# Tooling/Fixturing and Gauge

**Assumptions Days/W** 

**eek Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**



# 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
**Minimum Calculated Cycles Time Projected Operating Pattern** 

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% P** **c s** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**



# 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; FEV assumes all 8 rivets
can be fastened at once taking 105 seconds out of the process

time. Also assume multi-station assembly line. 

# Minimum 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 (W eeks/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-** ** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

### End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material

A 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### North America

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **9,574**

**10**

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

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

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

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



### B 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls

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

### Page: 2 of 12 

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

DRAFT



## Technology Level: **5 Speed Versus 6 Speed Transmission** 

## OEM Operating Pattern (W eeks/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-** ** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

### End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **North America**

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **9,574**

**10**

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

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

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

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



### C 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

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



### File:09000064810ec171.xls

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

### Page: 3 of 12 

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

DRAFT



## Technology Level: **5 Speed Versus 6 Speed Transmission** 

## OEM Operating Pattern (W eeks/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-** ** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

### End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **North America**

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **9,574**

**10**

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

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



### D 

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

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

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

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

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

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

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

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

Assembly.

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

T1 or OEM for Final or Sub

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

Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly. 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

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

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

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

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

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

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

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.00**

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

**Mark-up $0.00** 

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

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

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A 

### Supplier for Subassembly.

**3 1** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

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

----- ----- ----- **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**Base Cost Impact to Vehicle: $0.00**  **$0.00 $0.00**  **$0.00 #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: #N/A**  **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls

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

### Page: 4 of 12 

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

DRAFT



## Technology Level: **5 Speed Versus 6 Speed Transmission** 

## OEM Operating Pattern (W eeks/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-** ** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**
**$/lb**
**(DB) Labor** 

**Rate**
**$/Hour**
**(DB) Burden** 

**Rate**
**$/Hour**
**(DB) Applied** 

**Burden**

**Rate**
**$/Hour Material** 

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

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

### End

**Item**
**Scrap**

**Rate**
**(DB) SG&A** 

**Rate**
**(DB) Profit** 

**Rate**
**(DB) ED&T/** 

**R&D**

**Rate**
**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **North America**

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **9,574**

**10**

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

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

**Packaging**
**Cost per**

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



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

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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

### PACKAGING CALCULATIONS: Packaging Type:

Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

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



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

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00
Returnable Dividers For Option 1 Pallet

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



### File:09000064810ec171.xls

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

### Page: 5 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**
**Study Case#:**
**System Description:**
**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item
**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 
**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  

### Minimum Calculated Cycles Time **MANUFACTURING ASSUMPTIONS**
**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**
**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: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item
**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 
**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 



### Minimum Calculated Cycles Time **MANUFACTURING ASSUMPTIONS**
**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**
**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!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

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

### Page: 7 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**
**Study Case#:**
**System Description:**
**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item
**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 
**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 



### Minimum Calculated Cycles Time **MANUFACTURING ASSUMPTIONS**
**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**
**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: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item
**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 
**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 



### Minimum Calculated Cycles Time **MANUFACTURING ASSUMPTIONS**
**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**
**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: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

-

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

-

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

-

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

-

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

-

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

-



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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-



### File:09000064810ec171.xls

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

### Page: 10 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**
**Study Case#:**
**System Description:**
**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-



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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-



### File:09000064810ec171.xls

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

### Page: 11 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**
**Study Case#:**
**System Description:**
**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls

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

### Page: 12 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**
**Study Case#:**
**System Description:**
**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



### File:09000064810ec171.xls

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