i 

CONTENTS 

Section Page

Executive Summary...................................................................................................................ES-1 

1 Introduction ........................................................................................................................ 1-1 

1.1 Objectives ................................................................................................................. 1-1 

1.2 Process Methodology and Key Supporting Documents ........................................... 1-3 

1.3 Manufacturing Assumptions..................................................................................... 1-7 

2 Technology Selection......................................................................................................... 2-1 

3 Comparison Bill of Materials............................................................................................. 3-1 

3.1 Overview................................................................................................................... 3-1 

3.2 Main Sections of Comparison Bill of Materials....................................................... 3-1 

4 Costing Methodology - Teardown, Process Mapping, and Costing .................................. 4-1 

4.1 Cost Methodology Fundamentals............................................................................. 4-1 

4.2 Serial and Parallel Manufacturing Operations and Processes .................................. 4-2 

4.3 Design Profit® Software Overview.......................................................................... 4-5 

4.4 Teardown Process Overview .................................................................................... 4-8 

4.5 Identifying Materials, Primary and Secondary Processes ........................................ 4-9 

5 Cost Model Overview ........................................................................................................ 5-1 

6 Indirect OEM Costs............................................................................................................ 6-1 

7 Costing Databases .............................................................................................................. 7-1 

7.1 Database Overview................................................................................................... 7-1 

7.2 Material Database ..................................................................................................... 7-3 

7.2.1 Overview ................................................................................................... 7-3 

7.2.2 Material Selection Process ........................................................................ 7-6 

7.2.3 Pricing Sources and Considerations.......................................................... 7-7 

7.2.4 Material Price Forecasting, Accuracy and Variation ................................ 7-8 

7.2.5 In-process Scrap ........................................................................................ 7-9 

7.2.6 Purchase Part – Commodity Parts........................................................... 7-10 

7.3 Labor Database ....................................................................................................... 7-11 
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7.3.1 Overview ................................................................................................. 7-11 

7.3.2 Direct Versus Total Labor, Wage Versus Rate....................................... 7-11 

7.3.3 Contributors to Labor Rate and Labor Rate Equation ............................ 7-13 

7.4 Manufacturing Overhead Database ........................................................................ 7-17 

7.4.1 Overview ................................................................................................. 7-17 

7.4.2 Manufacturing Overhead Rate Contributors and Calculations ............... 7-19 

7.4.3 Acquiring Manufacturing Overhead Data............................................... 7-20 

7.5 Mark-up (Scrap, SG&A, Profit, ED&T) ................................................................ 7-23 

7.5.1 Overview ................................................................................................. 7-23 

7.5.2 Mark-up Rate Contributors and Calculations ......................................... 7-25 

7.5.3 Assigning Mark-up Rates........................................................................ 7-29 

7.6 Packaging Database................................................................................................ 7-30 

7.6.1 Overview ................................................................................................. 7-30 

7.6.2 Types of Packaging and Selection Process ............................................. 7-31 

7.6.3 Support for Costs in Packaging Database ............................................... 7-31 

8 Shipping Costs.................................................................................................................... 8-1 

9 Manufacturing Assumption and Quote Summary Worksheet ........................................... 9-1 

9.1 Overview................................................................................................................... 9-1 

9.2 Main Sections of Manufacturing Assumption and Quote Summary Worksheet ..... 9-1 

9.3 Manufacturing Assumption and Quote Summary Detail Review ............................ 9-5 

10 Marketplace Validation.................................................................................................... 10-1 

11 Cost Model Analysis Templates ...................................................................................... 11-1 

11.1 Subsystem Cost Model Analysis Templates ........................................................ 11-1 

11.2 System Cost Model Analysis Template ............................................................... 11-5 

12 Operating and End-of-Life Costs ..................................................................................... 12-1 

13 Results for Case Study #0101 .......................................................................................... 13-1 

14 Sensitivity Analysis.......................................................................................................... 14-1 

15 GLOSSARY OF TERMS ................................................................................................ 15-1 
iii

LIST OF APPENDICES 

A.1 Powertrain – Vehicle Class Summary Matrix Excerpt – Case Study #0101 

B.1 Powertrian Package Proforma – Case Study #0101 

C.1 Comparison Bill of Materials Excerpt– Case Study #0101, Mini Cooper 1.6L I4 

Turbo, Direct Injection 

D.1 Design Profit® Mapping Symbols 

E.1 Material Database Excerpt 

E.2 Labor Database Excerpt 

E.3 Manufacturing Overhead Database Excerpt 

E4. Manufacturing Overhead Calculator Template 

E5. Mark-up Database Excerpt 

E6. Packaging Database Excerpt 

F.1 Manufacturing Assumption and Quote Summary (MAQS) worksheet detailed 

reference guide 

G.1 MAQS Worksheets (Sections A,B,E & F) – Case Study #0101 

H.1 Subsystem Cost Model Analysis Templates – Case Study #0101 

H.2 System Cost Model Analysis Template – Case Study #0101 
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LIST OF FIGURES 

Number Page

Figure 1-1: Cost Analysis Process Flow Steps & Document Interaction............................1-3 

Figure 4-1: Fundamental Steps in Costing Process .............................................................4-4 

Figure 4-2: Screen Shot of Process Mapping Using Design Profit® Software...................4-7 

Figure 4-3: Property Window for a Part Symbol Used in Process Mapping.......................4-8 

Figure 4-4: Injection Molded Primary Processing Map ....................................................4-11 

Figure 4-5: Operations Library – Design Profit® Database..............................................4-13 

Figure 4-6: Tool Library - Design Profit® Database ........................................................4-14 

Figure 4-7: Material Modification Library – Design Profit® Database............................4-15 

Figure 4-8: Fastening Library - Design Profit® Database ................................................4-16 

Figure 4-9: Example Illustrating the Various Levels Associated with Process Mapping a 

Vacuum Pump Base Support .......................................................................... 4-18 

Figure 5-1: Unit Cost Model – Costing Factors Included in Analysis ................................5-1 

Figure 7-1: Illustrates the change in Labor Rates between 2008 and 2015, Assuming a 

Negative 5% Annual Adjustment Factor (AFF)...............................................7-2 

Figure 7-2: Price Data for Significant Materials Identified in Case Study #0101 ..............7-4 

Figure 7-3: Price Data for Significant Materials Identified in Case Study #0101 (Materials 

Database Excerpt #2B) .....................................................................................7-5 

Figure 7-4: Historical 304 Stainless Steel Prices.................................................................7-7 

Figure 7-5: Projected Pricing for 304 Stainless Steel..........................................................7-9 

Figure 7-6: Labor Database Excerpt Highlighting Occupation Classification Codes, 

Descriptions, and Mean Hourly Wages ..........................................................7-12 

Figure 7-7: Labor Database Excerpt Showing Contributors to Total Labor Rate for Various 

Direct Labor Occupations...............................................................................7-16 

Figure 7-8: Manufacturing Overhead Database Excerpt Showing Standard Overhead Rates 

for CNC Turning............................................................................................. 7-18 

Figure 7-9: Mark-up Database Excerpt Highlighting the Rate Differences ( End Item Scrap, 

SG&A, Profit, and ED&T), for Three (3) Levels of Injection Molding, Based 

on Part Size and Complexity........................................ .....................7-24 
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Figure 9-1: Excerpt Illustrating Automated Link between OEM/T1 Classification Input in 

MAQS Worksheet and the Corresponding Mark-up Percentages Uploaded from 

the Mark-up Database..................................................................................9-2 

Figure 9-2: Example of Packaging Cost Calculation for a High Pressure Fuel Injector.....9-5 

Figure 11-1: Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem 

Cost Roll Up for the Fuel Induction Subsystem - New Technology Configuration 

- Case Study #N0101................. .................................................................11-3 

Figure 11-2: Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem 

Cost Roll Up for the Fuel Induction Subsystem - Base Technology Package - 

Case Study #B0101..................................................................................... 11-4 

Figure 11-3: Excerpt from System Cost Model Analysis Template Illustrating the Incrmental 

Subystem Cost Roll Up for Case Study #0101 - 2.4L I4, 16 Valve, DOHC, NA, 

PFI downsized to 1.6L I4, DOHC, Turbo GDI............................................... 11-6 

Figure 13-1: System Cost Model Analysis Template Illustrating the Incremental Subsytem 

Costs Roll Up for I4, Turbo, GDI Downsizing, Case Study #0101 ...............13-2 
vi

LIST OF TABLES 

Number Page

Table ES-1: Case Study #0101 Incremental Unit Cost Impact - Downsizing from a 2.4L I4, 16 

Valve, DOHC, NA, PFI Engine to a 1.6L I4, 16 Valve, DOHC, Turbo, GDI Engine

.............................................................................................................................. ES-2 

Table 7-1: Tier 1 Published SG&A and ED&T/R&D Rates for 2007 and 2008 ...................7-27 

Table 7-2: Standard Mark-up Rates Applied to Tier 1 and Tier 2/3 Suppliers Based on Size 

and Complexity Ratings .......................................................................................7-28 

Table 7-3: Generic Mark-Up Rate Classification Based on Component Size and Complexity

.......................................................................................................................... ...7-30

Table 13-1: Summary of Cost Analysis Assumptions for Case Study #0101..........................13-3 

Table 14-1: Cost Model Sensitivity Study Results ..................................................................14-1 
1 

Light-Duty Technology Cost Analysis Pilot Study 

Executive Summary 

The United States Environmental Protection Agency (EPA) contracted with FEV, Inc. to 

determine incremental direct manufacturing costs for a set of advanced light-duty vehicle 

technologies. The technologies selected are on the leading edge for reducing emissions 

of greenhouse gases in the future, primarily in the form of tailpipe carbon dioxide (CO2). 

In contrast to comparable cost analyses done in the past, which rely heavily on supplier 

price quotes for key components, this study is based to a large degree on teardowns of 

vehicles or vehicle systems that employ the new technologies, and of similar vehicles or 

systems without the new technologies. Analysts with expertise in automotive design, 

materials, and manufacturing then compare the teardown components and evaluate the 

differences. Using databases for materials, labor, manufacturing overhead, and mark-up 

costs, the overall cost to manufacture individual parts are calculated and summed into 

final results. A model consisting of an extensive set of linked spreadsheets and 

associated macros has been developed to perform the calculations, to track the input data, 

identify sources of information, describe assumptions used in the case study, and provide 

analysis tools (such as forecasting to future years). 

This report describes the study methodology in detail, and presents results for the first 

technology evaluated: stoichiometric, gasoline direct injection (GDI) with turbocharging 

on a downsized I4 engine, compared to an equivalent conventional I4 engine. These 

results are summarized in the following Table ES-1. 

As shown in Table 1, the two (2) subsystems having the greatest impact on incremental 

costs were the air induction subsystem ($258.89) and fuel induction subsystem ($107.32). 

In the case of the air induction subsystem, all components included in the cost analysis 

were absolute component costs (i.e., there were no cost offsets from the base technology 

configuration). The major cost contributors to the air induction subsystem included the 

turbocharger assembly ($151.85), tubes and hoses ($52.21), charged air cooler assembly 

($18.65), and the OEM engine and vehicle assembly of air induction components 

($25.70). The major cost contributors associated with the adoption of a high pressure 

fuel induction subsystem included the addition of a high pressure fuel pump ($69.61), 

four (4) high pressure fuel injectors ($13.13/each) and a high pressure fuel rail ($20.76). 

These cost additions were offset by the base technology configuration costs which 

included four (4) low pressure fuel injectors ($8.77/each) and a low pressure fuel rail 

($5.83). 

Complete cost details for all subsystems referenced in Table ES-1 can be found in 

Appendices G.1 (individual component cost sheets), H.1 (subsystem cost roll ups) and 

H.2 (system cost roll up). 

ES- 
2

Table ES-1: Case Study #0101 Incremental Unit Cost Impact - Downsizing from a 2.4L I4, 16 

Valve, DOHC, NA, PFI Engine to a 1.6L I4, 16 Valve, DOHC, Turbo, GDI Engine

$0.00

Crank Drive Subsystem $0.00

Counter Balance Subsystem ($35.95)

Cylinder Block Subsystem $0.44

Cylinder Head Subsystem $16.55

Valve Train Subsystem $10.06

Timing Drive Subsystem $1.60

Accessory Drive Subsystem $0.00

Intake Subsystem ($12.73)

Fuel Induction Subsystem $107.32

Exhaust Subsystem $37.77

Lubrication (Oil Pans/Sumps) Subsystem $34.46

Cooling Subsystem $41.56

Induction Air Charging Subsystem $258.89

Exhaust Gas Re-Circulations Subsystem $0.00

Breather Subsystem $4.17

$56.61

$16.95

TOTAL UNIT COST $537.70

Engine Management, Engine Electronic and 

Electrical Subsystem

Accessory (e.g. Starter Motor, Power Steering 

Pump, Air Conditioning Compressor) Subsystem

Engine Frames, Mountings & Brackets Subsystem

Net Incremental 

Component/Assembly Cost 

Impact to OEM

Engine Subsystems

ES-
1-1 

1 Introduction 

1.1 Objectives 

This report describes the methodology used for the light-duty vehicle technology cost 

study performed for the Environmental Protection Agency (EPA) by FEV and its 

subcontractors. Because the methodology is most readily understood in the context of an 

actual case study, this report also presents details and results for the first technology 

studied: stoichiometric gasoline direct injection (GDI) with turbocharging on a 

downsized I4 engine, compared to an equivalent conventional I4 engine (Case Study 

#0101). Detailed analysis working documents for the case study are provided in the 

Appendix; however, the very large size of some of the analysis spreadsheets precludes 

their inclusion in the report itself and these are being made available in CD form or on 

EPA’s website (http://www.epa/gov/otaq/). Costing results and details for additional 

technologies and vehicle classes will be provided in subsequent reports. 

The objective of this work assignment is to determine incremental direct manufacturing 

costs for a set of advanced light-duty vehicle technologies. The technologies selected are 

on the leading edge for reducing emissions of greenhouse gases in the future, primarily in 

the form of tailpipe carbon dioxide (CO2). Such reductions generally correspond to fuel 

economy improvements. Each technology selected is evaluated against a baseline 

vehicle technology configuration, representative of the current state of design, and having 

similar overall driving performance. To obtain cost results across the diverse light-duty 

vehicle fleet, application of the new technologies in five (5) vehicle size classes is 

considered, though no costing is performed for cases in which a technology is not 

generally considered applicable to a vehicle class. The vehicle size classes are: 

• Small car: a subcompact or compact car typically powered by an in-line 4 cylinder 

engine 

• Midsize car: a midsize or large passenger car typically powered by a V6 engine 

• Large multi-purpose vehicle: a minivan or large cross-over vehicle with a large 

frontal area, typically powered by a V6 engine, capable of carrying ~ 6 or more 

passengers 

• Small truck: a small or mid-sized sports-utility or cross-over vehicle, or a small pickup truck, powered by a V6 or V8 engine 

• Large truck: large sports-utility vehicles and large pickup trucks, typically powered 

by a V8 engine 
1-2

Currently, the new technologies under consideration for study are: 

• Downsized turbocharged gasoline direct-injection (GDI) engines 

• Hybrid electric vehicles 

• Advanced transmissions (6-speed, dual clutch) 

• High-efficiency, low-leak air conditioning 

• Advanced diesel engines 

• Plug-in hybrids 

• Full electric vehicles 

• Homogenous charge compression ignition engines 

• Lean-burn GDI engines 
1-3

1.2 Process Methodology and Key Supporting Documents 

 

Figure 1-1: Cost Analysis Process Flow Steps & Document Interaction 

1. Technology 

Selection 

Powertrain Vehicle 

Class Summary Matrix 

(P-VCSM) 

2. Hardware 

Selection 

Powertrain Package 

Proforma 

3A. Generate Bill of 

Materials – Phase 1 

Comparison Bill of 

Materials (C-BOM)

Databases (Material, Labor, Manufacturing 

Overhead, Mark-up, & Packaging) 

5. Cross Functional 

Team (CFT)

Reviews 

7. Generate 

Manufacturing 

Assumption and 

Quote Summary 

(MAQS) 

Worksheets 

9. Subsystem Cost 

Roll Up 

Subsystem Cost Model 

Analysis Template

(Subsystem CMAT) 

10. System Cost 

Roll Up 

System Cost Model 

Analysis Template

(System CMAT) 

4. System/Subsystem 

Disassembly and 

Process Mapping – 

Phase 1 

(Design Profit®) 

6. Component/ 

Assembly 

Disassembly & 

Process Mapping – 

Phase 2 

(Design Profit®)

3B. Update Bill of Materials – Phase 2 

Comparison Bill of Materials (C-BOM)

8. Market Place 

Cross-check 

Process Flow 

Manual & Automated 

Document Links 
1-4

The overall process methodology is comprised of ten (10) major steps, described briefly 

below and in Figure 1, and in more detail in subsequent sections. 

Step 1: Using the Powertrain-Vehicle Class Summary Matrix (P-VCSM) a technology 

is selected for cost analysis. 

The P-VCSM identifies the technologies being evaluated, the applicable vehicle 

classes for each technology, and key parameters for vehicles or vehicle systems 

that have been selected to represent the new technology and baseline 

configurations in each vehicle class to be costed. As the defining input to the cost 

analysis, it is developed through extensive discussions with EPA. A portion of the 

P-VCSM for this case study is provided in Appendix A.1. This document may be 

modified as the study progresses. Note that some closely associated technologies 

are bundled; for example: gasoline direct injection and turbocharging. 

Step 2: Existing vehicle models are identified for teardown, to provide the basis for 

detailed incremental cost calculations. The teardown vehicles are chosen in collaboration 

with EPA to represent the base and new technology cases on the P-VCSM. For many 

technologies being studied the vehicle systems involved are not extensive, so that entire 

vehicles need not be torn down or costed out, but rather engines, transmissions, or other 

major components are targeted instead. In doing so, close scrutiny is paid to vehicle 

components that might be indirectly affected by the addition of a new technology, such 

as those needed for noise, vibration, and harshness (NVH) mitigation. The system and 

performance details of the selected new and base technology configurations are recorded 

in the Powertrain Package Proforma. 

The Powertrain Package Proforma is a summary worksheet comparing the key 

physical and performance attributes of the technology under study with those of 

the corresponding base configuration. The Powertrain Package Proforma for case 

study #0101 may be found in Appendix B.1. 

Step 3: Pre-teardown Comparison Bills of Materials (CBOM) are developed, covering 

hardware that exists in the new and base technology configurations. These high level 

CBOM’s are informed by the team’s understanding of the new and base technologies and 

serve to identify the major systems and components targeted for teardown.

The CBOM is a bill of materials which lists out all the subsystems and 

components associated with the technology configurations under evaluation. It 

may include subsystems or components of the new technology vehicle that are not 

used on the base vehicle. 

The CBOM provides a means of identifying all the parts that are different between 

the base and new technology configurations, as a result of adoption of the new 

technology. Also the CBOM is the document used to capture alternative design 
1-5

and manufacturing innovations, which can be binned to either material cost 

reduction (MCR) ideas or new technology advances (NTAs), within the 

technology configurations under evaluation. These ideas, if found to be of 

significant value, are then evaluated in terms of performance and/or cost 

improvements over the base assessment. 

In addition, the CBOM documents sources of the quote assumptions made for the 

cost analysis, e.g., parts, drawings or specifications, actual parts or surrogate, 

make or buy (purchase), validation quote required, etc. In the context of this 

study, “quote” generally refers to the analytically determined cost of a part or 

assembly, not a price provided by a supplier. A portion of the new technology 

configuration CBOM for case study #0101 may be found in Appendix C.1. 

Step 4: Phase 1 (high level) teardown is conducted for all subsystems identified in Step 

3 and the assemblies that comprise them. Using Design Profit® software, all high level 

processes (e.g. assembly process of the high pressure fuel pump onto the cylinder head 

assembly) are mapped during the disassembly. 

Process mapping is the sequential identification and orderly documentation of all 

the steps involved in a making an assembly or component. A single component 

may be manufactured using a number of processes (die casting, machining, 

washing, heat treating, anodizing, testing, etc). Each process may by further 

divided into several operations. Thus for a given assembly, often consisting of 

twenty (20) or more components, keeping track of processes and operations in a 

logical manner is very critical. 

Fundamental to process mapping is identifying the materials and the primary 

processes required to manufacture a part. This is followed by selecting the 

optimal manufacturing inputs (tools, equipment, etc.) based on certain 

manufacturing assumptions (see Section 1.3), such that a series of operations 

defining the process can be mapped. All parts requiring a detailed cost analysis 

undergo this process. 

Step 5: A cross functional team (CFT) reviews all the data generated from the high level 

teardown. This CFT, with an average relevant experience level of 23 years, employs 

technology expertise from several areas including: engine design and development, NVH 

and driveline subsystems, vehicle integration, production development, manufacturing 

engineering (supplier and OEM), cost estimating and product benchmarking. Where 

appropriate, personnel changes are made to the CFT to ensure matching expertise to the 

technology under analysis. 

The CFT captures the assessments in the CBOMs, identifying the component and 

assembly differences between the new and base technology configurations. All 
1-6

components requiring cost analysis are identified, as well as any base assumptions where 

applicable (e.g. material selection, primary and secondary manufacturing processes).

Step 6: Phase 2 (component/assembly level) teardowns are done, based on the updated 

CBOM’s. Components and assemblies are disassembled, and processes and operations 

are mapped in full detail. The process mapping generates key process information for the 

quote worksheets. Several databases, containing critical costing information, provide 

support to the mapping process. 

Step 7: Manufacturing Assumption and Quote Summary (MAQS) worksheets are 

generated for all parts undergoing the cost analysis. The MAQS details all cost elements 

making up the final unit costs: 

 material 

 labor 

 burden 

 end item scrap 

 selling, general & administrative (SG&A) 

 profit 

 engineering design & testing (ED&T) 

 packaging 

In addition the MAQS worksheet has active links to all key costing parameters. 

The MAQS worksheet is basically a standard original equipment manufacturer 

(OEM) quote sheet modified with some extra sections to display additional details 

as well as provide ease and flexibility for updating specific cost factors. The main 

feeder documents to the MAQS worksheet include the Design Profit® maps and 

costing databases. 

Two (2) key sections to the MAQS worksheet are the manufacturing assumption 

section and the quote summary section. In the manufacturing assumption section, 

key output variables from the process maps created by Design Profit® software 

are imported into the MAQS worksheets. Calculations are made with these inputs 

developing a mass production processing methodology. 

Outputs from the manufacturing assumption section of the MAQS worksheet are 

uploaded into the quote summary section along with various inputs from the 

various costing databases to arrive at a final estimated manufacturing cost. 
1-7

Step 8: Parts with high or unexpected cost results are subjected to a marketplace crosscheck such as comparison with supplier price quotes, or wider consultation with 

company and industry resources beyond the CFT. 

Step 9: All costs calculated in the MAQS worksheets are automatically inputted into the 

Subsystem Cost Model Analysis Templates (CMAT). Some examples of subsystems, 

contained within the engine system, include the following: crankdrive subsystem, 

cylinder head subsystem, fuel induction subsystem, and air induction subsystem. 

The Subsystem CMAT is used to display and roll up all the differential costs 

associated with a subsystem. All parts in a subsystem that are identified for 

costing in the CBOM are entered into the Subsystem CMAT. Also both the base 

and new technology configurations are included in the same CMAT to facilitate 

differential cost analysis. 

Step 10: The final step in the process is creating the System CMAT which rolls up all 

the subsystem differential costs to establish a final system unit cost. For case study 

#0101, the engine system was the only vehicle system requiring analysis. 

The System CMAT, similar in function to the subsystem CMAT, is the document 

used to display and roll-up all the subsystem costs associated within a system, as 

defined by the CBOM. Within the scope of this cost analysis, the System CMAT 

provides the bottom line incremental unit cost, between the base and new 

technology configurations under evaluation. All Subsystem CMAT totals are 

linked directly to the System CMAT. 

1.3 Manufacturing Assumptions 

When conducting the cost analysis for the various technology configurations, a number 

of assumptions are made in order to establish a consistent framework for all costing. The 

manufacturing assumptions can be broken into generic and specific case study 

assumptions. 

The generic manufacturing assumptions apply to all technology configurations under 

analysis. Listed below are the fundamental assumptions: 

1) All OEM and supplier manufacturing locations are in North America, unless 

otherwise stated. This serves to make the resulting costs conservative to the 

extent that OEMs use offshore suppliers to reduce costs. 

2) OEMs and suppliers have manufacturing equipment and facilities capable of 

handling required manufacturing processes and capacities, unless otherwise 

stated. 
1-8

3) All manufacturing processes and operations are based on standard/mainstream 

industrial practices. 

4) Supplier mark-up rates (End-Item Scrap, SG&A, Profit, ED&T) are based on 

mature technology and manufacturing methods (e.g. mature product designs, high 

production volumes, significant marketplace competition, established 

manufacturing processes) unless otherwise specified. 

5) All OEM mark-up will be applied using indirect cost (IC) multipliers. These are 

not within the scope of this analysis, but should be separately determined and 

applied to the results of this analysis to obtain total (direct + indirect) 

manufacturing costs. 

6) Manufacturing rates are considered high volume (450,000 units per year for case 

study #0101) and maintained throughout the product life. The engine volume 

assumption for case study #0101 is based on published data from Ward’s 

Automotive Yearbook 2008, in which annual engine volumes for 2007 model 

year US domestic light-vehicle production ranged from 350K to 480K for 

moderate to high volume consumption applications. 

The specific case study assumptions are those unique to a given technology 

configuration. These include volume assumptions, weekly operation assumptions (days, 

shifts, hours, etc.), packaging assumptions, and Tier 1 in-house manufacturing versus 

Tier 2/3 purchase part assumptions. Details on the case study specific assumptions can 

be found in the individual MAQS worksheets.
2-1 

2 Technology Selection 

The Powertrain-Vehicle Class Summary Matrix (P-VCSM) summarizes the technology 

configurations and vehicle classes to be evaluated. Using the design parameters listed in 

the P-VCSM, the best-suited hardware is chosen for the new technology and base 

configurations. The performance attributes being matched in these configurations, along 

with other pertinent vehicle/system details, are listed in the Powertrain Package Proforma 

for each case study. 

As discussed in Section 1.1, five (5) vehicle classes were considered for this work 

assignment. Costing based on full teardowns in every relevant vehicle class would be 

prohibitively expensive and time consuming. Fortunately, reliable results can be 

obtained through judicious scaling of the teardown-derived costs, up or down, across the 

relevant vehicle classes. In some cases, teardown of a limited set of key components 

from a vehicle in a particular class assists in scaling costing results to that class. 

Proper scaling of teardown results is a complex but critical part of the overall analysis, 

and the methodology for it can vary, component by component. Some parts are best 

scaled by engine displacement (cylinder block, turbocharger assembly, oil pump 

assembly, for example) and some by number count (number of pistons, for example) or 

other parameters. The P-VCSM identifies which case studies have been conducted using 

the full teardown and cost analysis method and those which have used the scaling 

methodology. The scaling assumptions for individual components are documented in the 

quote assumption section of the CBOM. 
3-1 

3 Comparison Bill of Materials 

3.1 Overview 

The CBOM’s function as the case study road maps, detailing what is being quoted and 

why. The CBOM records all the high level details of the technology configurations 

under study, identifies those items which have cost implication as a result of the new 

versus base technology differences, documents the study assumptions, and captures input 

from the cross functional team. 

The CBOM’s are considered working documents, and as such are updated and referenced 

throughout the different phases of the analysis. All costing documents are referenced 

back to the CBOM’s, linking all components of the analysis. 

In addition to the manufacturing cost impact on components and assemblies directly 

associated with new technologies, the “ripple effect” on neighboring systems must be 

considered. These effects may have positive or negative consequences on the overall 

vehicle costs for the new technologies. 

When a new case study is initiated, the cross functional team meets to discuss the primary 

differences between the base and new technology configurations being studied as well as 

the surrounding systems, which may be affected by the technology differences. A 

Comparison Bill of Material is generated as a starting point to track all potential system, 

subsystem and component/assembly costs directly or indirectly associated with the 

technology change. Thus, regardless of what system or subsystem an affected 

component or assembly resides in, it is tracked and quoted using the same costing 

methodology. It should be noted that in this case study, where a naturally-aspirated I-4 

engine is replaced by a downsized, turbocharged I-4 engine, the team concluded that no 

additional costs were involved outside the engine system ( e.g. the firing frequency and 

overall power level of the two (2) engines are similar). In future studies, where there is a 

quantifiable difference in NVH or other characteristics between the base case and the 

new technology, the components required to address them will be identified and costed. 

3.2 Main Sections of Comparison Bill of Materials 

The CBOM consists of the following sections: 

The General Part Information section lists out all the systems, subsystems, and 

components potentially affected by going from the base configuration to the new 

technology configuration under consideration. The goal at this stage of the process is a 

conservative (long) list, with the expectation that detailed examination will subsequently 

eliminate some components from further consideration, as described below. The layout 
3-2

structure of the CBOM is top level down (system, subsystems, assemblies, etc.) All 

components and assemblies within subsystems, and all subsystems within systems, are 

grouped according to design function. 

The Design Difference section is where parts are identified as not needing cost analysis. 

All parts initially listed in the CBOM are identified as requiring cost analysis; represented 

with a red check box. Only after the cross functional team has reviewed the parts and 

determined they can be excluded from the study is the box checked off, turning it green 

to indicate no cost analysis is required. If exclusion of a part is not obvious, remarks are 

added identifying the team’s assumptions. If a checkbox is left red, identifying that the 

part requires cost analysis, the attribute differences are identified along with any study 

and costing assumptions. In several circumstances, the systems, subsystems, and 

components under comparison, between the base and new technology configurations, 

will be different in variety of ways: part existence, material selection, part geometry, 

manufacturing methods, etc. It is the job of the cross functional team to determine if 

these differences are driven by the change in technology, or are exclusive of the 

technology and the result of a supplier and/or OEM design and/or manufacturing 

preference. These decisions are documented in the CBOM. 

The Potential Material Cost Reduction (MCR) section captures potential design and/or 

manufacturing optimization for the hardware being evaluated. These savings could 

potentially reduce or increase the differential costs between the new and base technology 

configurations, depending on whether an MCR idea is for the new or the base 

technology. Typically base technology MCR actions are associated with efforts to share 

components across common platforms.

The New Technology Advances (NTA) section captures alternative advance technology 

ideas which could be substituted for some of the existing hardware being evaluated. 

These advanced technologies, through improved function and performance, and/or cost 

reductions, could help increase the overall value of the technology configuration. 

The MCR and NTA sections are intended to provide for cost optimization in the model 

from improvement opportunities explicitly identified in the teardown evaluations. 

However, this cost study uses these sections sparingly, emphasizing hardware “on the 

floor”, and therefore does not negate the appropriateness of applying “learning curves” 

for projecting future cost reductions in maturing technologies. 

The Quote Assumptions section provides the cost analysis roadmap for each part. The 

roadmap includes some of the following general items: 

1) “Make Versus Buy” indicates if a part is quoted with a full analysis, as if it were 

being made by the manufacturer, or is treated as a “buy”, with surrogate costs 

pulled from an applicable database. 
3-3

2) “Marketplace Validation” identifies which components should be cross-checked 

with market place data. 

3) “Component Information Source”, identifies what type of information is available 

for the quote, e.g., part, drawing, marked-up drawing/sketch, specification, or 

other. 

4) “Component Information Requires Assumption Modifications”, identifies for a 

given component what modifications or assumption changes are required to the 

information before the item is quoted. 

The Component Specification Assumptions section identifies the basic material, finish, 

functional and/or performance information associated with top level components where 

applicable. The information listed in this section facilitates the process mapping stage by 

identifying some of these core assumptions up front. This section is typically more 

beneficial for component type end items than for assemblies. For example, the material 

and heat treat level for a cylinder block can be identified up front, prior to the actual 

mapping process. In contrast, a high pressure fuel pump, which would exist in the CBOM 

as a complete assembly, would require disassembly so all part materials, finishes, etc., 

can be identified. 

The Component Manufacturing Assumptions section identifies the primary and 

secondary manufacturing processes associated with top level components. As for the 

Component Specification Assumptions, this information is used to help feed the process 

mapping stage. In addition, this section is better suited for end-item components than for 

assemblies. 

The Potential Component Suppliers section lists the typical suppliers who may 

manufacture similar types of parts as those identified in the CBOM. Understanding the 

typical supplier size and complexity characteristics associated with manufacturing a 

particular type of component facilitates the assignment of the mark-up rates to a 

particular component. Various mark-up rate groupings are established (methodology 

detailed in Section 7.5) based on supplier size and complexity. During the cost analysis 

suppliers are binned to these various mark-up groups which in turn define the mark-up 

rates for a particular component.
4-1 

4 Costing Methodology - Teardown, Process Mapping, and Costing 

4.1 Cost Methodology Fundamentals 

The costing methodology employed in this analysis is based on two (2) primary 

processes: (1) the development of detailed production process flow charts (P-flows), and 

(2) the transferring and processing of key information, from the P-flows, into standardize 

quoting worksheets. Supporting these two (2) primary processes with key input data, are 

the costing databases (e.g. material “price/lb”, labor “$/hour”, manufacturing overhead 

“$/hour”, mark-up “% of manufacturing cost” and packaging “$/packaging type”). The 

costing databases will be discussed in greater detail in Section 7. 

Process flow charts, depending on their defined function and end user, can very widely in 

the level of detail they contain; ranging from simple block diagrams showing the general 

steps involved in the manufacturing or assembly of an item, to very detailed process flow 

charts breaking out each process step in finite detail capturing key manufacturing 

variables. For this cost analysis, detailed P-flows, which will also be referred to as 

process maps, are used to identify all the steps involved in manufacturing a product (e.g. 

assembly, machining, welding, forming), at all levels (e.g. system, subsystem, assembly 

and component ). For example in a turbocharger scenario, process flows would exist for 

the following: (1) at the component level, the manufacturing of every component within 

the turbocharger (unless considered a purchase part), (2) at the assembly level, the 

assembly of all the individual components to produce the turbocharger, (3) at the 

subsystem level, the assembly of the turbocharger onto the engine, and (4) at the system 

level, the assembly of the engine into the vehicle. 

In addition to detailing pictorially the process steps involved for a given manufacturing 

process, having key information (e.g. equipment type, material type and usage, cycle 

times, handling precautions, number of operators) associated with each step is imperative. 

Understanding the steps and the key process parameters together creates the costing 

roadmap for any particular manufacturing process. 

Due to the vast and complex nature of P-flows associated with some of the larger system 

and subsystems under analysis, having specialized software which can accurately and 

consistently create and organize the abundant number of detailed P-flows becomes a 

considerable advantage. For this cost analysis Design Profit® software is utilized for 

producing and managing the process flows. Information regarding the details of Design 

Profit® software will be covered in the next section. 

The second major step in the cost analysis process involves taking the key information 

from the process flows and uploading it into a standardized quote worksheet. The quote 

worksheet, referred to as the Manufacturing Assumption and Quote Summary (MAQS) 
4-2

worksheet, is essentially a modified generic OEM quoting template. Every assembly 

included in the cost analysis (excluding commodity purchased parts) has a completed 

MAQS worksheet capturing all the cost details for the assembly. For example all the 

components and their associated costs, required in the manufacturing of a turbocharger 

assembly, will be captured in Turbocharger Assembly MAQS worksheet. In addition, a 

separate MAQS worksheet detailing the cost associated with assembling the turbocharger 

assembly to the engine, along with any other identified air induction subsystem 

components, would be created. 

In addition to process flow information feeding into the MAQS worksheet, data is also 

automatically linked in from the various costing databases. More discussion on the 

MAQS worksheet, interfaces, and complete function is captured in Section 9. 

4.2 Serial and Parallel Manufacturing Operations and Processes 

For purpose of this analysis, serial operations are defined as operations which must take 

place in a set sequence; one at a time. For example, fixturing metal stamped bracket 

components before welding can commence, both the fixturing and welding are 

considered serial operations within the bracket welding process. Conversely, parallel 

operations are defined as two (2) or more operations which can occur simultaneously on 

a part. An example of this would be machining multiple features into a cylinder block 

simultaneously. 

A process is defined as one (1) or more operations (serial or parallel) coupled together to 

create a component, subassembly, or assembly. A serial process is defined as a process 

where all operations (serial and/or parallel) are completed on a part before work is 

initiated on the next part. For example, turning a check valve body on a single spindle, 

CNC screw machine, would be considered a serial process. In comparison, a parallel 

process is where different operations (serial and/or parallel) are taking place 

simultaneously at multiple stations on more than one (1) part. A multi-station final 

assembly line, for assembling together the various components of a vacuum pump, would 

be considered a parallel process. 

As discussed, the intent of a process flow chart is to capture all the individual operations 

and details required to manufacture a part (e.g. component, subassembly, assembly). In 

many cases this results in a string of serial operations, generating a serial process, which 

requires additional analysis to develop a mainstream mass production process (i.e., 

inclusion of parallel operations and processing). The Manufacturing Assumption section 

of the MAQS worksheet, is where the base assumptions for converting serial operations 

and processes, into mass production operations and processes, is captured. 

For example, assume “Assembly M” requires fifteen (15) operations to assembly all of its 

parts together; each operation on average taking approximately ten (10) seconds to 
4-3

complete. In a serial process (analogous to single, standalone work cell, manned by a 

single operator) consisting of fifteen (15) serial operations, the total process time would 

be 150 seconds to produce each part (15 operations x 10 second average/station). Taking 

this serial assembly process, and converting it into a mass production parallel process, the 

following scenarios could be evaluated (Note rates and assumptions applied below are 

fabricated for this example only): 

1. Scenario #1: 15 serial operation stations, all manned, each performing a single 

operation in parallel. 

• Process Time 10 seconds/part, 360 parts/hour @ 100% efficiency 

• Labor Cost/Part = [(15 Direct Laborers)*(Labor Rate $30/hour )]/360 

parts/hour = $1.25/part 

• Burden Cost/Part = [(15 Stations)*(Burden Rate Average (Low 

Complexity Line) $15/hour/station)]/360 parts/hour = $0.625/part 

2. Scenario #2: 15 serial operations combined into 10 stations, 5 with 2 parallel 

automated operations, 5 serial manual operations. 

• Process Time 10 seconds/part, 360 parts/hour @ 100% efficiency, 

• Labor Cost/Part = [(5 Direct Laborers)*(Labor Rate $30/hour )]/360 

parts/hour = $0.42/part 

• Burden Cost/Part = [(10 Stations)*(Burden Rate Average (Moderate 

Complexity Line) $30/hour/station)]/360 parts/hour = $0.83/part 

Assuming a high production volume in a North America manufacturing base (two key 

study assumptions), scenario #2 would have been automatically chosen; higher level of 

automation offsetting higher manual assembly costs. 

For components whose typical mass production process is a serial process (e.g., injection 

molding, stamping, die casting, selected screw machining) the manufacturing assumption 

section of the MAQS worksheet requires far less consideration. Analysis is usually 

limited to determining the total number of pieces of equipment required for the defined 

volume. 

Figure 4-1 illustrates the fundamental steps incorporated into the cost methodology. 
4-4

Figure 4-1: Fundamental Steps in Costing Process

1. Select Component

Assembly, Subsystem, and /or System, for cost analysis 3. Develop Process Flow Charts (Also referred to as Process Maps)

During all levels of the teardown, process flow charts capturing every manufacturing operation are generated, including all key variables associated with each operation. Examples of the operations and part details include:> operation description, equipment specification, cycle times, material composition/specification, component geometry, component mass, etc.Tools used to create Process Maps:> Design Profit® Software using Lean Design® Module > Munro & Associates Cost Estimator Model/Tools

 4. Populate Standardized Quote Worksheets - Two Main Functional Se(Also referred to as Manufacturing Assumption and Quote Summary (MAQS) works

 Manufacturing Assumptions (Section D of MAQS)Using the data generated from the Process Flow Charts, multiple calculations are performed establishing the mass production manufacturing assumptions.Examples included the following:

> OEM and Supplier classifications are selected, based on 

component type and processes, establishing the applicable markup rates> Serial operations are combined into parallel operations where applicable> Operations, both serial and/or parallel, are grouped into high volume parallel processes where applicable. > Equipment numbers calculated to support capacity requirements> Final equipment selection and associated burden rates are established> Calculate number of operators required to support defined manufacturing process> Piece per hours calculated

 Quote Summary  (Sections B,C,E & F)Using the data generated in the Manufacturing Assumption SectioMAQS, along with data from the CDatabases, a net component/assimpact is calculated.Information used in final calculations ifollowing:

> Calculated pieces/hour

 > Material specification, quantity, and price/poun > Labor Classification, number of operators, and  > Burden Classification, number of machines, an > OEM/Supplier Classification, percent of total mcosts > Packaging Container, cost per container, numbcontainer 

 Costing Databases Support Process Mapping and Quote Worksheet Phases of Cost Analysis

Five (5) Databases store rates for all eight cost elements used within the cost analysis: Material, Labor, Burden, Mark-up (E

Scrap, SG&A, Profit, and ED&T) and Packaging 

2. Conduct ControlledTeardown Process
4-5 

4.3 Design Profit® Software Overview 

Design Profit® software, has been chosen as the primary tool for creating detailed 

process flow charts, also referred to as process maps, for the cost analysis. The Design 

Profit® software consists of several modules each providing unique application specific 

functions. The process mapping module, within Design Profit® Software, is referred to 

as Lean Design®. Design Profit®, owned and developed by Design Profit, Inc., was 

started in 1995 to encompass the Lean Design® and Quality Report Card® 

methodologies developed by Munro & Associates, Inc. 

The Design Profit® methodology is a quantitative, analytical, database-driven approach 

to mapping manufacturing operations and processes, providing a consistent means of 

capturing the essence of manufacturing. The software resides on a central server which 

allows for multiple users to work within the same project utilizing the exact same 

databases. This further ensures consistency through out the project as additional 

personnel can be added while minimizing the learning curve typically associated with 

most projects. 

The software provides a visual representation of the product through the use of 

symbology depicting various assembly and manufacturing processes. Figure 4-2 is a 

screenshot of the Design Profit® software and the mapping process used to generate 

product, process and operation metrics. There are various symbols used in developing 

process maps, each having a unique meaning such as part type, part level, process, 

operation, etc. Reference Appendix D.1 for symbol examples and associated descriptions. 

Each symbol is generated by filling out a properties window, which assigns key 

manufacturing information to the symbol. These details include operator-to-part 

interfaces, part-to-part interfaces, machine operations, etc., which provide the basic 

assembly time associated with the operation. Additional data includes part name, part 

number, part description, weight, quantity, material and supplier if known. Figure 4-3 is 

a screenshot of a part input screen. 

The majority of manufacturing information/specifications uploaded during the mapping 

process are acquired directly from pre-established internal libraries/databases 

incorporated within the Design Profit® software. These internal databases have been 

loaded, validated and maintained by Munro & Associates Inc., a partner in the cost 

analysis studies. 

In addition to manufacturing information inputted directly from internal Design Profit® 

software libraries, external costing tools are also used to generate manufacturing data for 

the process maps. These external cost estimating models commonly handle all the 

primary fabrication processes (e.g. injection molding, stamping, die casting). More 

details on these external cost estimating models are covered in Section 4.5. 
4-6

Design Profit® uses a combination of automated testing and dedicated developers who 

test and develop test cases. In addition to in-house testing and validation, the metrics and 

algorithms in Design Profit® have gone through scrutiny over the last fifteen (15) years 

and have proven to be accurate for automotive volume and small to medium size parts. 

The customized internal libraries have been refined to include standard labor rates, 

assembly processes, and manufacturing processes. This level of customization provides 

repeatability and consistency in analysis. Design Profit® also provides the ability to input 

customer-known variables where component size and/or difficulty of assembly are 

outside the prediction abilities for Design Profit®. 
4-7 

Figure 4-2: Screen Shot of Process Mapping Using Design Profit® Software 
4-8 

Figure 4-3: Property Window for a Part Symbol Used in Process Mapping 

4.4 Teardown Process Overview 

The teardown methodology utilized for the analysis is a multi-tiered approach. First, a 

high level teardown is initiated. This process consists of identifying the high level 

modules within each system/subsystem and mapping them in the Design Profit® 

software. This provides a means of determining when/where various components are 
4-9

assembled and to what content level, providing insight to differentiate OEM- vs. 

supplier-assembled components. During the high level teardown process, updates are 

made to the CBOM to ensure all high level assemblies and assumptions are accurately 

recorded. The CBOM provides the first glimpse of what the true differences are 

between the two vehicle technologies. At this point assemblies are identified that will 

require further disassembly to establish cost deltas. 

After the comparison review, the second level of teardown commences. As with the 

high level reviews, all steps associated with the assembly of the components are 

captured within the Design Profit® software. Also at this point all primary 

manufacturing processes are captured. The vast majority of the parts identified for cost 

deltas are disassembled down to individual components, each manufactured from a 

single material. 

During both the high level and the detailed teardowns, all attributes of the parts are 

captured, including assembly characteristics, materials, quantities, and weights; photos 

are also taken. Once the parts are disassembled in their entirety, they are then put 

through the Design Profit® costing tools to develop the serial manufacturing process 

times. Throughout the process a number of databases and costing tools are used to feed 

essential data into Design Profit® Maps. These databases include but are not limited to: 

raw material specifications and prices, OEM labor rates, machine burden rates, various 

costed BOMs, and supplier processes and operations. 

4.5 Identifying Materials, Primary and Secondary Processes 

Key steps in the cost analysis, for each individual part, are identifying the materials and 

the primary processes used in making the part. Once these have been identified, 

appropriate costing models are selected to calculate the primary fabrication parameters 

(e.g. raw material usage, cycle times, equipment size, number of cavities per tool). This 

is followed by capturing the secondary processes and parameters associated with 

manufacturing the part (e.g. machining, welding, assembly). 

Material identification is accomplished in one of three ways. The simplest method is 

observing material identification markings on the part itself. Because of recyclability 

directives set in place in Europe, most manufactures will cast/mold in the material 

properties. For components which are not marked, such as pistons and crankshafts, the 

first approach to accessing the specific material composition is consultation with FEV’s 

and Munro’s CFT members. If there are still materials which cannot be identified a 

selection of publications are referenced, and/or manufacturers and experts within the 

supplier community are contacted to establish credible material choices. 

Next the primary manufacturing process must be established. Most all of the processes 

typically leave little tell-tale signs as to how the part is manufactured. If the part is die 
4-10

cast, for example, there will be ejector pin marks and distinct parting lines, while sand 

and semi-permanent molding techniques are typically utilized when there are internal 

hollow sections formed by cores. A semi-permanent mold casting will have parting 

lines and no ejector pin markings, while a sand casting will typically have little to no 

signs of parting lines or ejector pin markings. In the case of no tell-tale signs (less than 

2% of parts) of the primary processes, an outside subject matter expert is contacted. 

Once the primary material and manufacturing processes have been identified the part 

can then be cost estimated. To accomplish this various cost estimating models, 

developed by Munro & Associates Inc are utilized. These models provide various key 

outputs including cycle times and equipment sizes for the particular part being cost 

estimated. All of the models require a number of manual input parameters which may 

include some or all of the following depending on the primary process selected: part 

length, width, height, weight (or volume), material, nominal wall thicknesses, material 

thickness, number of bends, number of punched holes, part projected area, part 

perimeter and the number of cavities. The models also account for part variability 

through a factoring methodology. These include tolerances, appearance, parting lines, 

complexity, number of planes with die lock, and profiles in the case of extrusions. 

The models use these input factors within formulas to establish the output results. The 

fixed formulas also take into account various material and processing specifications 

including material density, tensile strengths, thermal diffusivity, injection pressures, die 

temperatures, mold temperatures, ejection temperatures, press sizes, press stroke rates, 

extrusion rates etc. The library of costing models used for the study includes, but not 

limited too, the following: aluminum (die casting, semi-permanent mold, sand casting, 

metal injection molding and powdered metal), plastics/composites (injection molded 

and extruded), and steel/iron (casting, forging, stamping, investment cast, and 

powdered metal). Figure 4-4 provides a snap shot of the process mapping and how the 

cost models are tied into the process maps for a large injection molded part. 

All of the cost models are put through a validation process to ensure the results are 

reflective of current technologies and known costs of components. An example of this 

process would be validation of the injection molding module. Three (3) different size 

parts with assorted features are selected to ensure diversity of the model. The parts 

selected are typically chosen from the most recent projects that had available cost data. 

The part parameters are then input into the model and the results are directly compared 

to the actual known costs of the current parts. 
4-11 

Figure 4-4: Injection Molded Primary Processing Map 
4-12 

After the primary process analysis has been completed, the secondary processes are 

addressed. The Design Profit® software is utilized to capture all secondary operations 

and processes to ensure consistency throughout the costing exercise. These secondary 

processes include all aspects of machining, surface treatments, joining methods, etc. All 

operation and process details are stored in various libraries (Design Profit® databases) 

which are readily available for reuse in additional analyzes. For example drilled holes 

are categorized in the Material Modification Library by depth of hole, as this is typically 

the cycle time driver. 

The actual cycle time, and other operation details, for items captured in the libraries are 

based on a number of parameters depending on the actual process being analyzed. As an 

example, the machining times are based on typical feeds and speeds associated with the 

specific material being removed, and/or based on averages from available processing data 

(machining bill of materials), and/or actual listed equipment capabilities. In other 

situations the process time may be calculated based on distance calculations i.e. applying 

RTV is based on seconds per inch. Each of these processes is mapped within their own 

string of symbols and is assigned burden rates dependent on the actual equipment 

required. See Figure 4-5 through 4-8 for snap shots of the actual libraries found within 

the Design Profit® software. 
4-13 

Figure 4-5: Operations Library – Design Profit® Database 
4-14

Figure 4-6: Tool Library - Design Profit® Database 
4-15

Figure 4-7: Material Modification Library – Design Profit® Database 
4-16

Figure 4-8: Fastening Library - Design Profit® Database 
4-17 

Figure 4-9 is a sample excerpt displaying the various steps associated with a vacuum 

pump base component and how it was mapped using the Design Profit® software. The 

vacuum pump is assumed to be purchased by the OEM and its’ assembly to the vehicle is 

represented on the top line of the map (Symbols 121 thru 127). The top line is assigned a 

labor rate, based on OEM assembly, pulled from the labor database. The next line below 

the OEM is the assembly of the various parts at the supplier level and is assigned a 

supplier general assembly labor rate, also pulled in from the labor database (11 of 30 

symbols shown). The pump base was identified as a die cast machined part based on part 

attributes, and was further analyzed with the third line representing the casting being 

machined on a CNC machine with the appropriate burden rate being selected from the 

burden database. The machining total time was estimated at 122 seconds based on all of 

its discreet features (7 of the 45 symbols shown). The last line of symbols represents the 

casting as its primary manufacturing method. To establish the casting cost a number of 

inputs are required in the cost modeling tool. In the case of the pump base the material 

was identified as Aluminum A380 with a raw material cost of $1.10 pulled from the 

material database. Additional inputs required to calculate the part cost included the 

following for die casting: annual volume (450,000), years of production (5), wall 

thickness (0.25 inches), part length (5.4 inches), part width (4.6 inches), part depth (1 

inch), part projected area (24.84 square inches), part weight after machining (0.4733 

pounds), number of planes with die lock features (2) and number of cavities in the tool 

(4). These inputs are then utilized to establish the actual material required for the casting 

accounting for sprue and runner lengths associated with the process; material required 

was estimated to be 0.542 pounds for the raw casting. The tool calculates the press size 

(tonnage) based on the number of parts and their total project area estimating the clamp 

load required to prevent die separation (~173 ton theoretical) This is then used to 

establish the actual equipment to determine the appropriate burden rate associated with 

the casting. The tool then calculates the cycle time for the machine establishing injection 

time (2.4 sec) cooling time (60.36 sec) resetting time (5.4 sec) and die lubricating time 

(10.5 sec) for a total cycle time of 78.6 seconds divided by the number of cavities 

resulting in 19.7 seconds per part. The cycle time is input into the Design Profit® 

symbols actual time cell and all others are zeroed out. 
4-18 

 Figure 4-9: Example Illustrating the Various Levels Associated with Process Mapping a Vacuum Pum

Casting Process 

Machining Process 

Supplier 

Assembly 

Labor 

OEM 

Assembly 

Labor 
5-1 

5 Cost Model Overview 

The cost parameters considered in determining the net incremental component/assembly 

impact to the OEM for new technologies are discussed in detail below.

Unit Cost is the sum of total manufacturing cost (TMC), mark-up costs and packaging 

cost associated with producing a component/assembly. It is the net component/assembly 

cost impact to the OEM (generally, the automobile manufacturer). Figure 5-1 shows all 

the factors contributing to unit cost for supplier manufactured components. Additional 

details on the subcategories are discussed in the sections that follow. 

Net Component/Assembly Cost 

Impact To OEM

Total Manufacturing 

Cost

Raw Material

Packaging Cost

=

+

Manufacturing 

Overhead/ Burden

Material

Labor

In-process Scrap

Purchased Part - 

Commodity Parts

Direct Labor Indirect Labor

Maintenance, 

Repair, Other Fringe

=

+

+

Mark-up Cost

End Item Scrap

=

+

+

Sell, General & 

Administrative 

Costs

Profit

Engineering, Design 

and Testing/R&D

+

+

Primary 

Equipment

Process 

Supporting Equip.

General Plant & 

Office Equip. Facilities

Utilities Plant Salary

Corporate Overhead: personnel functions, 

finance/accounting, systems data 

processing, sales/marketing, purchasing, 

public relations, legal staff, training, 

warranty, etc

Quality Defects Destruct Tests

Shipping Damage

Project Support 

ED&T

Corporate R&D

Supplier compensation for the assumption 

of investment risk in supplying a part to a 

customer.

Figure 5-1: Unit Cost Model – Costing Factors Included in Analysis 

For OEM manufactured components/assemblies, the unit cost is calculated in the same 

way, except that mark-up is addressed outside the scope of this study through application 

of indirect cost (IC) multipliers. The IC multiplier assigned is based on the technology 

complexity level and timeframe in the market place; see Section 6 for additional details. 
5-2

The full report, “Automobile Industry Retail Price Equivalent and Indirect Cost 

Multipliers” EPA report EPA-420-R-09-003, February 2009, can be downloaded from 

http://www.epa.gov/OMSWWW/ld-hwy/420r09003.pdf. 

Shipping Costs are those required to transport a component between dispersed 

manufacturing and assembly locations, including any applicable insurance, tax, or 

surcharge expenses. Shipping costs between T2/T3 and T1 suppliers are captured as part 

of the mark-up rate except where special handling measures are involved. For T1 

supplier to OEM facilities, the shipping costs are captured using the IC multiplier that 

replaces mark-up as discussed above. Additional details on shipping costs are discussed 

in Section 8. 

Tooling Costs are the dedicated tool, gauge and fixture costs required to manufacture a 

part. Examples of items covered by tooling costs are: injection molds, casting molds, 

stamping dies, weld fixtures, assembly fixtures, dedicated assembly and/or machining 

pallets, and dedicated gauging. For this analysis, all tooling is assumed to be owned by 

the OEM and the differential cost impact is accounted for through the application of an 

IC multiplier. 

Investment Costs are the manufacturing facility costs, not covered as tooling, required to 

manufacture parts. Investment costs include manufacturing plants, manufacturing 

equipment (e.g. injection mold machines, die cast machines, machining and turning 

machines, welding equipment, assembly lines), material handling equipment (e.g. lift 

forks, overhead cranes, loading dock lifts, conveyor systems), paint lines, plating lines, 

and heat treat equipment. Investment costs are covered by manufacturing overhead rates 

and thus are not summed up separately in the cost analysis. Additional details on how 

investments expenses are accounted for through manufacturing overhead can be found in 

Section 7.4. 

Product Development Costs are the ED&T costs incurred for development of a 

component or system. These costs can be associated with a vehicle specific application 

and/or be part of the normal research and development (R&D) performed by companies 

to remain competitive. In the cost analysis, the product development costs for suppliers 

are included in the mark-up rate as ED&T. More details are provided in Section 7.5. For 

the OEM, the product development costs are captured in the IC multipliers that replace 

mark-up, as discussed in the unit cost section above. 

In summary, the two (2) main cost elements (TMC and Mark-up), in the supplier unit 

cost model defined in Figure 5-1 includes considerations for shipping, investment and 

product development costs. For the OEM, investment costs are accounted for in the 

OEM Unit cost model via the TMC. Shipping, tooling and product development costs 

are accounted for as part of the IC multiplier addressed outside the scope of this study. 
5-3

Lastly, the “Net Incremental Component /Assembly Cost Impact to OEM” is defined as 

the summation of the supplier and OEM unit costs, for all the identified component and 

assembly differences, between the new and base technology configurations. 

A more detailed discussion on the elements which make-up the unit cost model follows. 
6-1 

6 Indirect OEM Costs 

In addition to the direct manufacturing costs, a manufacturer also incurs certain indirect 

costs. These costs may be related to production, such as research and development 

(R&D); tooling; corporate operations, such as salaries, pensions, and health care costs for 

corporate staff; or selling, such as transportation, dealer support, and marketing. Indirect 

costs incurred by a supplier of a component or vehicle system constitute a direct 

manufacturing cost to the OEM (the original equipment (vehicle) manufacturer), and thus 

are included in this study. The OEM’s indirect costs, however, are not included and must 

be determined and applied separately to obtain total manufacturing costs. These indirect 

costs are beyond the scope of this study and are applied separately by EPA staff in their 

analysis. A brief discussion of this follows. 

In February 2009, EPA issued a report, “Automobile Industry Retail Price Equivalent and 

Indirect Cost Multipliers,” written by Alex Rogozhin and Michael Gallaher of RTI 

International and Walter McManus of the University of Michigan Transportation 

Research Institute. The discussion in this section is taken from that report. 

The RPE/IC report provides a new calculation of the retail price equivalent (RPE) 

multiplier commonly used to estimate the indirect costs associated with a new 

technology. The RPE is a ratio of total revenue to direct manufacturing cost; put another 

way, it is the ratio of indirect costs plus profit to direct manufacturing costs. It is an 

average over all the activities of a manufacturer. However, a problem in using RPE 

multipliers in regulatory analysis is that some of the indirect cost components of the RPE 

multiplier, such as fixed depreciation costs, health care costs for retired workers, or 

pensions, may not be affected by all vehicle modifications resulting from regulation. In 

addition, RPEs assume that market prices will increase by the full cost plus constant 

profit of the new technology; in fact, other factors that influence price (especially 

consumer demand and preferences) will affect how much of those costs will be passed 

along into market price. 

The RPE/IC report develops a modified multiplier, referred to as an IC multiplier, which 

specifically evaluates the components of indirect costs that are likely to be affected by 

vehicle modifications associated with environmental regulation. A range of IC 

multipliers are developed that 1) account for differences in the technical complexity of 

required vehicle modifications and 2) adjust over time as new technologies become 

assimilated into the automotive supply chain. 

ICMs are calculated in the RPE/IC report to range from 1.05 to 1.45 in the short run and 

from 1.02 to 1.26 in the long run. The differences between the short- and long-run IC 

multipliers are primarily due to R&D and warranty costs, which are projected to 

decrease over time. R&D expenditures also vary greatly over the level of technology 

complexity, as does the need for dealer support. To use the multipliers in the RPE/IC 
6-2

report, analysts can start by assessing the degree of complexity of the new technology 

under consideration. That identification process will lead to the short-run and long-run 

multipliers for the new technology. If an analyst has additional information about the 

role of indirect cost contributors for the new technology, that information can be used to 

develop project-specific adjustment factor. 
7-1 

7 Costing Databases 

7.1 Database Overview 

The Unit Cost Model shown in Figure 5-1 illustrates the three (3) main cost element 

categories, along with all the core subcategories, which make up the unit costs for all 

components and assemblies in the analysis. 

Every cost element used throughout the analysis is extracted from one of the core 

databases. There are databases for material prices ($/pound), labor rates ($/hour), 

manufacturing overhead rates ($/hour), mark-up rates (% of TMC) and packaging 

($/packaging option). The databases provide the foundation of the cost analysis, since all 

costs originate from them, and they are also used to document sources and supporting 

information for the cost numbers. Excerpts from all five (5) databases may be found in 

Appendix E.1-E.6. 

The model allows for updates to the cost elements which automatically roll into the 

individual component/assembly cost models. Since all cost sheets and parameters are 

directly linked to the databases, changing the “Active Rate” cost elements in the 

applicable database automatically updates the Manufacturing Assumption Quote 

Summary (MAQS) worksheets. Thus if a material doubles in price, one can easily assess 

the impact on the technology configurations under study. 

The model also includes a forecasting feature associated with each database to project 

changes from the baseline cost data. For each database there is a baseline data set based 

on 2008 figures, and two (2) additional “projected cost” data sets which reference back to 

this baseline dataset. The projected cost data sets can be specified either manually or by 

using the Annual Adjustment Factor (AAF) feature. The AAF feature is basically a 

depreciation/interest calculator where the user defines a period, and a percent rate of 

growth or decline relative to the baseline. To illustrate the AFF feature, an exaggerated

gross decline of 5% per year, from 2008 through to 2015, was entered into the labor 

database to create a mock 2015 forecasted data set (see Figure 7-1). Changing the active 

rate value in the database from 2008 to 2015 loads the new dataset; all cost sheets are 

automatically updated with the 2015 labor projections. 

Additional details are provided for each database in the following sections.
7-2 

Figure 7-1: Illustrates the change in Labor Rates between 2008 and 2015, Assuming a Negative 5% A

(AFF) 
7-3 

7.2 Material Database 

7.2.1 Overview

The Material Database houses specific material prices and related material information 

required for component cost estimating analysis. The information related to each 

material listed includes the material name, standard industry identification (e.g. AISI or 

SAE nomenclature), typical automotive applications, pricing per pound, annual 

consumption rates, and source references. The prices recorded in the database are in US 

dollars per pound. The database provides for input of forecasted future year prices; a 

discussion of the forecasting methodology follows. Figure 7-2 and Figure 7-3 provide 

the price data for significant materials identified in the cost study analysis. 
7-4 

Active Rate

2008

A. CARBON & ALLOY STEELS (SAE1000-900

A1. CARBON STEEL

A1.1 10XX Plain Carbon Steel Mn 1.00% Max

Low Carbon Steel SAE J403 1008/1010 Coil Brackets, Spacers LC-Steel-1000S, Coil 0.45 $ 

Medium Carbon Steel SAE J403 1018 Coil Splash Pans, Dampers, Windage Tray MC-Steel-1000S, Coil $ 0.55

Low Carbon, Hot Dip Galvanized 

Steel.

SAE J403 1008/1010 Coil PCV Baffles LC-GSteel-1000S, Coil $ 0.48

Medium Carbon Steel SAE J403 1018 Bar MC-Steel-1018, Bar $ 0.74

High Carbon Steel SAE J403 1040 Bar (1-3") HC-Steel-1040S, Bar 0.80 $ 

A1.3 12XX Resulfurized and Rephosphorized

1215 Replacement to 12L14 Bar Bushings, Inserts, Couplings LC-Steel-1215, Bar 0.62 $ 

Low Carbon Steel Tubing 1215 Tube Metal Tubing coolant lines, oil lines, etc. LC-Steel-1215, Tubing 0.62 $ 

A6. CHROMIUM-MOLYBDENUM (CHROMOLY) STEELS

A6.1 41XX

41xx Bar Injector Body A-Steel-41XXS, Bar 0.78 $ 

Chrome-Moly-Vanadium Steel 32CrMoV13 Bar Bearings, Crank shafts MA-Steel-CrMoV, Bar 0.98 $ 

4140RH 42CrMoS4 Bar Crankshafts, axle journals, gears, pushrods. A-Steel-4140, Bar 0.78 $ 

4130 C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil, 0.04" to 0.125" HC-Steel-4130, Coil 

0.04"-0.125"

$ 1.18

4130 Tight Thickness Tolerance. C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil, 0.05" to 0.08", Tight 

Thickness Tolerance

HC-Steel-4130, Coil 

0.04"-0.08"

$ 2.79

A7. NICKLE-CHROMIUM-MOLYBDENUM STEELS

A7.1 43XX Ni 1.82%, Cr 0.50-0.80%, Mo 0.25%

300M SAE 4340Mod Vacuum melted high 

strength, super alloy.

Drive shafts, Con. Rods MA-Steel-300M, Bar 0.89 $ 

Ni-Chrome-Moly SAE 4330/4340 Bar 1-7" Planetary Gear Carrier, Shafts MA-Steel-43XXM, Bar 1.08 $ 

B. HIGH STRENGTH LOW ALLOY (HSLA) and MICRO ALLOY STEELS

B2. Micro Alloy Steels

C70S6 C0.72%, Si0.22%, Mn0.49%, S0.062%, 

V0.04%

Typical Air Cooled Forging 

Steel Forged fractured split rods MA-Steel-C70S6, Bar 0.70 $ 

36MnVS4 Bar Crankshafts, Cracked Forged Rods, Short and Long-shaft 

Ball Points, threaded heavy duty anchor bolts. MA-Steel-MnVS, Bar 0.73 $ 

C. STAINLESS STEELS (SAE100-600Series)

C1. 300 Series - Austenitic Chromium-Nick

C1.1 304 General Purpose

304 Bar Valves and Tubing S-Steel-304, Bar 1.65 $ 

304/304L Coil Exhaust Systems, Fuel tanks S-Steel-304, Coil 1.64 $ 

304/304L Sheet or Cast Housings for Catalytic Converters and Turbochargers. S-Steel-304, Cast 1.39 $ 

304 Tube Fuel Rail S-Steel-304, Tube 1.65 $ 

C1.1.1 316 Mo added to increase corrosion resistance.

316 Bar Valves and Tubing S-Steel-316, Bar 2.44 $ 

316/316L C reduced for weldability Coil S-Steel-316, Coil 2.72 $ 

316/316L C reduced for weldability Cast/Sheet Housings for Catalytic Converters and Turbochargers. S-Steel-316, Cast 2.82 $ 

C1.1.2 309/309S CR & Ni increased for high temperature.

310/310S Same as 309, only more so. Internal Components for Turbochargers (e.g.. Rotors) S-Steel-310, Cast 4.23 $ 

D. CAST IRONS

D1. Nodular/Ductile Cast Iron

Nodular / Ductile Iron (80-55-06) ASTM A536-80-55-06 $0.90-$1.2/lb finished 

casting

Crankshaft, blocks Nodular Iron, Cast 0.35 $ 

Nodular / Ductile Iron (100-70-03) ASTM A536-100-70-03 $0.90-$1.2/lb finished 

casting

High Strength Cam shafts i.e.., driving HP fuel pumps. Nodular Iron, 

Gr100/70/03, Cast

$ 0.42

Ni-resist cast iron, D5S D5S, ASTM A-439-84 Housing - Turbo Exhaust NiResist Iron, D5S, 

Cast

$ 3.50

Silicon Molybdenum Cast Iron 4% Si & 1% Mo Housing-Block Center, Turbo Support SiMo Ductile Iron, Cast 0.60 $ 

D2. Malleable Cast Irons

Malleable Cast Iron $0.90-$1.2/lb finished 

casting

Crankshaft, camshafts, blocks Malleable Cast Iron 0.41 $ 

D3. Grey Cast Iron

Grey Cast Iron SAE J431 Grade 3000 (3.1-3.4C, 1.9-2.3Si, 

Mn 0.60-0.90)

Engine Blocks Grey Iron, Cast 0.35 $ 

E. ALUMINUM ALLOYS 

E1. Wrought Alloys

E1.2 3XXX Al-Mn Alloys

3003, 3005, 3012 Aluminum Magnesium Braze-clad welded radiator tubes, heater cores, radiator, 

heater and evaporative fins, heater inlet and outlet tubes, 

oil coolers, and air conditioner liquid lines, radiator heater 

and evaporative parts, extruded condenser tubes.

Aluminum-3000S, Coil $ 0.84

3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.032-0.125" (0.75-

3.15mm)

Heat Exchangers Aluminum-3003, Coil 

A

$ 1.41

3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.003-0.009" (0.075-

0.22mm)

Heat Exchangers Aluminum-3003, Coil 

B

$ 1.93

E1.3 4XXX Al-Si Alloys

4032 4032-T651 Bar Ø1.0-2.5" Aluminum-4032, Bar 1.44 $ 

3003-H14 Clad 4XXX Aluminum-Manganese Cladded Tube Seamless welded tube - 

thickness 0.012-0.02" (0.3-

0.5mm)

Heat Exchangers Cladded Aluminum3003, Tube$ 2.28

E2. Casting Alloys ( Hypoeutectic 8.5-10.5, Eutectic 11-12, 16-18 Hypereutectic Material )

3XX Al-Si + Cu and/or Mg Alloys

319 T5 Al-3.5Cu-6Si Hypoeutectic/Perm. Manifolds, cylinder heads, blocks, internal engine parts Aluminum-A319-T5, 

Cast

$ 1.15

332 / F132 8.5-10Si, 2.0-4.0Cu, Ni0.10 Hypereutectic, common 

grade, large recycled 

composition (Die.)

Hypoeutectic Aluminum-332, Cast 1.24 $ 

356 T6 or A356 7Si-0.3 Mg alloy Hypoeutectic (Perm.) Engine blocks, flywheel, oil pan, pump bodies, cyl heads, 

manifolds, transmission cases

Aluminum-356-T6, 

Cast

$ 1.20

A380.1 Al-9Si-3Cu(Fe) Hypoeutectic (Die.) Blocks, transmission housings/parts, fuel metering 

devices, oil pump cyl heads, 

Aluminum-A380, 

Cast

$ 1.10

 Carbon Ranges: Low 0.05-0.15%, Mid. 0.16-0.29%, High 0.30-1.10%, Ultra High 1-2%

Harden by cold working, can not be hardened by heat treating, Non Magnetic in annealed condition. Excellent corrosion resistance and 

usually good formability.

Typical Cast Irons are 95%wt. Iron, 2.1-4%wt Carbon, and 1-3%wt. Silicon.

(Temper Designations F>as Fabricated, O>annealed, H> Strain-hardened, W>Solution heat-treated. T> Thermally 

treated, usually solution heat-treated, quenched and precipitation hardened.

Cr 0.50% 0r 0.80% or 0.95%, Mo 0.12% or 0.20% or 0.25% or 0.30%

Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class

A . C arbo n/ A llo y Steel

B. HSLA & M icro Alloy

C. Stainless Steel 

D. Cast Iron

H . T itanium A llo ys

G. M agnesium A llo ys

F . P o wder M etal J. C o pper A llo ys

E. A luminum A llo ys

M .

Q. Thermoplastics

R Thermosets.

P . S. Thermoplastic Elast.

N .

L C o balt A llo ys. O.

K. N ickel A llo ys T .

U Automotive Fluids.

V. P lating & Coatings

W M isc.

X.

Y.

Figure 7-2: Price Data for Significant Materials Identified in Case Study #0101 

(Materials Database Excerpt #2A) 
7-5

Figure 7-3: Price Data for Significant Materials Identified in Case Study #0101 

(Materials Database Excerpt #2B)

Active Rate

2008

B380 Al-9Si-3Cu(Fe) Hypoeutectic (Die) Blocks, transmission housings/parts, fuel metering 

devices, oil pump cyl heads, 

Aluminum-B380, 

Cast

$ 1.18

384 Eutectic (Die) Pistons, automatic transmissions Aluminum-384, Cast 1.14 $ 

B390.0 Hypereutectic aluminum-silicon Hypereutectic (Die.) High-wear applications such as ring gears and internal 

transmission parts, Hypereutectic pistons, cylinder blocks

Aluminum-B390, 

Cast

$ 1.20

H. TITANIUM WROUGHT & CASTING ALLOYS

H1. Wrought Alloys

Titanium (6AL V4) Bar High Pressure Bellows Pump Titanium-6AL4V, Bar 34.37 $ 

J. COPPER WROUGHT & CASTING ALLOYS (BRONZE & BRASS)

J6.3 High Lead Tin Bronze & Lead Free Bronze (LC-M/H, T=H, C/E=G RS=G, H/W=H)

C93200 SAE 660 Bearing Bronze bushings, pump fixtures, pump impellers, fuel pump 

bushings, thrust washers, insert bearings, gears, valves 

and valve components, etc.

Bronze-932, Bar 2.56 $ 

C89320 Lead Free Replacement to C93200 89%Cu, 6%Sn, and 5%Bi Turbocharger Spindle Bushings (Floating Type) Bronze-89320, Bar 2.56 $ 

Oilite Bronze Bearing Alloy SAE841 1" Round Bar $ 5.31

J6.4 Aluminum Bronze(LC-VH, T=VH, C/E=P RS=M, H/W=VH)

ASTM C63000, C63020 Nickel Aluminum Bronze Valve stems and trim, bearings and bushings, fasteners, 

gears

Ni-Al-Bronze-630000, 

Bar

$ 2.44

J6.12 Silicon Brasses (LC=? , T=? , C/E=? , RS=?, H/W=?)

C87500 (500) Silicon Brass, 82-4Si-14Zn Bearings, gears, impellers, rocker arms, valve stems, brush 

holders, bearing races, small boat propellers.

Si-Brass-87500, Bar 2.11 $ 

CDA 673 - Silicon Manganese 

Brass

C67300 Bar Si-Brass-67300, Bar 3.71 $ 

J6.13 Brass General 

C36000 CDA 360 Fluid connectors, threaded inserts for plastic parts, sensor 

bodies, thermostat parts

Brass-36000, Bar 1.70 $ 

J6.14 Cooper General 

Copper >99.0% Pure Wire harnesses Copper-Pure, Wire 2.45 $ 

K. NICKEL WROUGHT & CASTING ALLOYS

K1. Wrought Alloys

K1.1 Inconel®

Inconel® 713 Coil Coil Heat Shields, Turbo Inconel-713C, Coil 6.00 $ 

Nickel Alloy - Internal Turbo Parts General Coil Heat Shields, Turbo Nickel Alloy Gen, Cast 5.00 $ 

Inconel® 713 Coil Cast Inconel-713, Cast 6.00 $ 

Q. THERMOPLASTIC POLYMNERS

Q1. Polyamide (PA/Nylon)

Nylon 6 PA6 Nylon6, Inject. 1.65 $ 

Nylon 6 (15 % glass) PA6 GF15 Air cooler tube outlet Nylon6-15GF, Inject. 1.59 $ 

Nylon 6 (30 to 35% glass) PA6 GF30 Vacuum reservoir, Intake manifold Nylon6-30GF, Inject. 1.76 $ 

Nylon 66 PA66 Fuel injector connector, hose asm end - pump to turbo, 

chain tension guides

Nylon66, Inject. 1.74 $ 

Nylon 66 (30 to 35% glass) PA66 GF30 Intake manifold, cylinder cover, cooler asm end caps Nylon66-30GF, Inject. 1.54 $ 

Nylon 66 (50% glass) PA66 GF50 cooler asm end caps Nylon66-50GF, Inject. 1.54 $ 

Nylon 66, 40% Fibrous Mineral 

Reinforced

PA66 FMR40% GMNA Spec PA66 060 Direct Injection Connectors Nylon66-40FMR, Inject $ 1.54

Nylon 12 PA12 Reservior tube Nylon12, Inject. 3.03 $ 

Nylon 12, 30% glass PA12, GF30 PCV Hose Intake End $ 3.41

Q3. Polyethylene

HDPE Copolymer - blowmolding HDPE Rubberized blow molded air induction ducts and couplings. HDPE BM Grade 0.72 $ 

Q4. Polybutylene Terephthalate (PBT)

Polybutylene Terephthalate PBT GF20 Silencer Air by-pass PBT-GF20, Inject. 1.46 $ 

Q6. Polypropylene (PP)

Random copolymer blow molding 

grade.

PP High strength blow molded air induction ducts. HD Polypro 0.87 $ 

Q9. Polyvinylchloride (PVC)

Blended NBR-PVC Rubberized blow molded air induction ducts and couplings. NBR-PVC 1.27 $ 

R. THERMOSET POLYMERS

R1 Hydrocarbon, Unsaturated.

Natural rubber / TSR20 NR Hoses, O-rings, gaskets, tubes Thermoset-NR 2.14 $ 

Synthetic poly-isoprene rubber IR Hoses, O-rings, gaskets, tubes Thermoset-IR

Styrene butadiene rubber SBR Hoses, O-rings, gaskets, tubes Thermoset-SBR 1.32 $ 

Polubutadiene rubber - glass filled PBR GF20 Auxiliary water pump housing Thermoset-PBR-GF20 1.17 $ 

Butyl rubber IIR Hoses, O-rings, gaskets, tubes Thermoset-IIR 1.37 $ 

R3. Nitrile

Nitrile butadiene rubber NBR Hoses, O-rings, gaskets, tubes Thermoset-NBR 1.27 $ 

R8. Fluorocarbon

Fluoro elastomer FKM ERG valve seals Thermoset-FKM 12.50 $ 

R10. Polyimide

Polyimide - Vespel SP-21 PI 30%Carbon filled thrust washers, bearings and seals — low-friction 

properties, work with or without lubrication.

Thermoset-Vespel 

SP21CF30

$ 35.18

Polyimide - Vespel SP-21 PI 30%Glass filled Thermoset-Vespel 

SP21GF30

$ 24.36

R12. Polyurethane

Polyurethane elastomer, esterbasedAU Hoses, O-rings, gaskets, tubes Thermoset-AU 1.77 $ 

R13. Silicone

Silicone rubber MVQ Hoses, O-rings, gaskets, tubes Thermoset-MVQ 4.50 $ 

R14. Miscellaneous

SBR Tubing w. Fiber Reinforcement SBR Reinforced Tubing SBR-Fiber Rein., 

Extruded

$ 1.85

SBR Tubing w. Metal 

Reinforcement

SBR Reinforced Tubing SBR-Metal Rein., 

Extruded

$ 2.24

SBR Tubing w. Fiber Reinforcement 

and outer wrap.

SBR Reinforced Tubing SBR-Fiber Rein. W. 

Outer Wrap, Extruded

$ 2.05

Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class

A . C arbo n/ A llo y Steel

B. HSLA & M icro Alloy

C. Stainless Steel 

D. Cast Iron

H . T itanium A llo ys

G. M agnesium A llo ys

F . P o wder M etal J. C o pper A llo ys

E. A luminum A llo ys

M .

Q. Thermoplastics

R Thermosets.

P . S. Thermoplastic Elast.

N .

L C o balt A llo ys. O.

K. N ickel A llo ys T .

U Automotive Fluids.

V. P lating & Coatings

W M isc.

X.

Y.
7-6 

The applications identified for a material also help determine the annual consumption 

rate which impacts whether high or low volume prices are used. The annual consumption 

rate assigned to a particular material is determined by its weight, usage and uniqueness. 

For example, a single polypropylene cover on an engine assembly represents a very 

minor usage and weight contribution to the engine. Polypropylene, however, is a 

common high usage resin. Therefore, despite its limited use in this application a high 

annual consumption rate pricing is applied. This resin is readily available, and the part 

can be obtained from any number of competitive molding companies that regularly 

manufacture these types of components. A Viton® fluoroelastomer engine seal, on the 

other hand, is specified as a low annual consumption rate material. This component also 

represents a very minor usage and weight contribution to the engine, but, in addition, this 

resin is a specialty material. It is known for its excellent heat and chemical resistance, 

and is used sparingly for certain engine end-use applications. For case study #0101, only 

material pricing corresponding to high annual volume consumption was considered. 

7.2.2 Material Selection Process

The materials listed in the database are resins and ferrous and non-ferrous alloys used in 

the products and components selected for cost analysis. The materials identification 

process is based on visual part markings, part appearance and part application. Material 

markings are the most obvious method of material identification. Resin components 

typically have material markings (for example, >PA66 30GF<) which are easily 

identified, recorded in the database and researched to establish price trends. 

For components which are not marked, such as pistons and crankshafts, the FEV and 

Munro cross functional team members are consulted to help in the materials 

identification. For any materials still not identified, information published in print and on 

the web is researched, or primary manufacturers and experts within the Tier 1 supplier 

community are contacted to establish credible material choices. 

The specific application and the part appearance play a role in materials identification. 

Steels commonly referred to as work-hardenable steels with high manganese content 

(13% Mn) are readily made in a casting and are not forgeable. Therefore establishing 

whether a component is forged or cast can narrow the materials identification process. 

Observing visual cues on components can be very informative. Complex part geometry 

alone can rule out the possibility of forgings; however more subtle differences must be 

considered. For example, forged components typically have a smoother appearance to 

the grain whereas cast components have a rougher finish, especially in the areas where 

machining is absent. Castings also usually display evidence of casting flash. 

The component application environment will also help determine material choice. There 

are, for example, several conventional ductile cast iron applications found in base 

gasoline engines that are moving to Ductile High Silicon - Molybdenum or Ductile Ni-
7-7

Resist cast irons in downsized turbocharged engines. This is due to high temperature, 

thermal cycling, and corrosion resistance demands associated with elevated exhaust gas 

temperatures in turbocharged engines. Therefore understanding the part application and 

use environment can greatly assist in more accurate material determinations. 

7.2.3 Pricing Sources and Considerations

The pricing data housed in the database is derived from various sources of publicly 

available data from which historical trend data can be derived. The objective is to find 

historical pricing data over as many years as possible to obtain the most accurate trend 

response. Ferrous and non-ferrous alloy pricing involves internet searches of several 

sources, including the U.S. Geological Survey (USGS), MEPS (previously Management 

Engineering & Production Services), Metalprices, estainlesssteel and Longbow. Figure 

7-4 is a snap shot of historical steel prices for US stainless steel grade 304 sheet compiled 

from estainlesssteel and purchasing.com. 

Figure 7-4: Historical 304 Stainless Steel Prices 

Resin pricing is also obtained from sources such as Plastics News, Plastics Technology 

Online, Rubber and Plastics News and IDES (Integrated Design Engineering Systems). 

Several other sources are used in this research as outlined in the database. 

Though material prices are often published for standard materials, prices for specialized 

material formulations and/or those having a nonstandard geometric configuration (e.g. 

length, width, thickness, cross-section), are not typically available. Where pricing is not 

available for a given material with a known composition, two (2) approaches are used: 

industry consultation and composition analysis. In cases such as Ni-Resist cast iron, 

which has several different possible pre-processed heat treatments, consultation with 

manufacturers of the component or similar components is required. 
7-8

Obtaining prices for unknown proprietary material compositions, such as powder metals, 

necessitated a standardized industry approach. In these cases manufacturers and industry 

market research firms are consulted to provide generic pricing formulas and pricing 

trends. Their price formulas are balanced against published market trends of similar 

materials to establish new pricing trends. In terms of ferrous alloys, the database must 

also take into account unique or non-standard material thicknesses. Any specified nonstandard sheet or plate thickness requires additional mill runs and must be priced 

accordingly. In this case, price estimations from consultations with industry 

manufacturers in conjunction with similar material pricing trend data are utilized. 

Resin formulations are also available with a variety of fillers and filler content. Some 

pricing data is available for specific formulations; however pricing is not published for 

every variation. This variation is significant since many manufactures can easily tailor 

resin filler type and content to serve the specific application. Consequently, the database 

has been structured to group resins with a common filler, into ranges of filler content. 

For example, glass filled Nylon 6 is grouped into three (3) categories; 0 to 15 percent 

glass filled, 30 to 35 percent glass filled and 50 percent glass filled, each with their own 

price point. These groupings provide a single price point as the price differential within a 

group (0 to 15 percent glass filled) is not statistically significant 

7.2.4 Material Price Forecasting, Accuracy and Variation

Though it is very difficult to accurately predict future material prices, there are statistical 

methods, such as regression analysis, to help predict expected pricing outcomes based on 

past trends. Price movements can be greatly affected over a short period of time by 

unpredictable global economic movements and policies such as the price of oil or 

embargos. In order to mitigate sporadic anomalies, these extreme peaks and valleys in 

the data set, which normalize within short periods of time, are disregarded. 

Figure 7-5 illustrates the power curve trend line applied to historical 304 stainless steel 

prices. Other trend line plotting options (exponential, linear, etc.) are available; however, 

the power trend line obtains what is felt to be a realistic upward trend line response in this 

case. Each material data history is evaluated to establish the best fit line and 

corresponding projection. However, it should be noted that, for the case study presented 

in this report, a sensitivity analysis has been performed in lieu of calculating future 

technology cost impacts based on these data-based material-by-material price projections. 

Subsequent case analyses are expected to make use of these projections. 
7-9

Figure 7-5: Projected Pricing for 304 Stainless Steel 

7.2.5 In-process Scrap

In-process scrap is defined as the raw material mass, beyond the final part weight, 

required to manufacture a component. For example in an injection molded part, the inprocess scrap is typically created from the delivery system of the molten plastic into the 

part cavity (e.g. sprue, runners and part gate). This additional material is trimmed off 

following part injection from the mold. In some cases, dependent on the material and 

application, a portion of this material can be ground up and returned into the virgin 

material mix. 

In the case of screw machine parts, the in-process scrap is defined as the amount of 

material removed from the raw bar stock in the process of creating the part features. 

Generally, material removed during the various machining processes is sold at scrap 

value. Within this cost analysis study, no considerations were made to account for 

recovering scrap costs. 

A second scrap parameter accounted for in the cost analysis is end-item scrap. End-item 

scrap is captured as a cost element within mark-up and will be discussed in more detail 

within the mark-up database section (Section 6.5). Although it is worth reiterating here 

that in-process scrap only covers the additional raw material mass required for 

manufacturing a part. It does not include an allowance for quality defects, rework costs 

and/or destructive test parts; these costs are covered by the end-item scrap allowance. 
7-10

7.2.6 Purchase Part – Commodity Parts

In the quote assumption section of the CBOM, parts are identified as either “make” or 

“buy”. The “make” classification indicates a detailed quote is required for the applicable 

part, and “buy” indicates an established price based on historical data is used in place of a 

full quote work-up. Parts identified as a “buy” are treated as a purchased part. For the 

first case study, no attempt was made to split purchased part costs into material, labor, 

and burden components. In this case purchased part costs are binned solely as material 

costs. 

Many of the parts considered to be purchased are simple standard fasteners (nuts, bolts, 

screws, washers, clips, hose clamps) and seals (gaskets, o-rings). However, in certain 

cases more value-added components are considered purchased when sufficient data 

existed supporting their cost as a commodity, that is, where competitive or other forces 

drive these costs to levels on the order of those expected had these parts been analyzed as 

“make” parts. 

Purchased part costs are obtained from a variety of sources. These include FEV and 

Munro team members’ cost knowledge, surrogate component costing databases, Tier 1 

supplier networks, published information, and service part cost information. Although an 

important component of the overall costing methodology, purchase part costs are used 

judiciously and conservatively, primarily for mature commodity parts. 
7-11 

7.3 Labor Database 

7.3.1 Overview

The Labor Database contains all the standard occupations and associated labor rates 

required to manufacture automotive parts and vehicles. All labor rates referenced 

throughout the cost analysis are referenced from the established Labor Database. 

The labor classification format of the database is created using the same methodology as 

the Bureau of Labor Statistics (BLS). Further, the core labor wage data used throughout 

the study, with exception of fringe and wage projection parameters, is acquired from the 

BLS. 

The Labor Database is broken into (2) two primary industry sections, Motor Vehicle 

Parts Manufacturing (supplier base) and Motor Vehicle Manufacturing (OEMs). These 

(2) two industry sections correspond to the BLS, North American Industry Classification 

System (NAICS) 336300 and 336100 respectively. Within each industry section of the 

database, there is a list of standard production occupations taken from the BLS Standard 

Occupation Classification (SOC) system. For reference, the base SOC code for 

production occupations within the Motor Vehicle Parts Manufacturing and Motor 

Vehicle Manufacturing is 51-0000. Every production occupation listed in the Labor 

Database has a calculated labor rate, as discussed in more detail below. 

Labor rates for 2008 establish the reference baseline from which projected labor rates can 

be developed. An “Annual Adjustment Factor” is used to account for labor rate 

projections. The labor rates can be modified for each production occupation, or for the 

industry as a whole. 

7.3.2 Direct Versus Total Labor, Wage Versus Rate

Each standard production occupation found in the Labor Database has an SOC 

identification number, title, labor description and mean hourly wage taken directly from 

the BLS. Figure 7-6 is an excerpt from the Labor Database. 
7-12

Figure 7-6: Labor Database Excerpt Highlighting Occupation Classification Codes, 

Descriptions, and Mean Hourly Wages 

Only “direct” production occupations are listed in the database. Team assemblers and 

forging, cutting, punching, and press machine operators are all considered direct 

production occupations. There are several tiers of manufacturing personnel supporting 

the direct laborers that need to be accounted for in the total labor costs: quality 

technicians, process engineers, lift truck drivers, millwrights, electricians, etc. A method 

typically used by the automotive industry to account for all of these additional “indirect 

labor” costs, and the one chosen for this cost analysis, is to calculate the contribution of 

indirect labor as an average percent of direct labor, for a given production occupation, in 

a given industry sector. More details of this calculation are discussed in the next section. 

The BLS Database provides labor wage data, rather than labor rate data. In addition to 

what a direct laborer is paid, there are several additional expenses the employer must 

cover in addition to the employee base wage. This analysis refers to these added 

employer expenditures as “fringe”. Fringe is applicable to all employees and will be 

discussed in greater detail below. 

It should be noted that the BLS motor vehicle and motor vehicle parts manufacturing 

(NAICS 336100&336300) labor rates include union and non-union labor rates, reflecting 

the relative mix of each in the workforce at the time the data was gathered (2007). 
7-13

7.3.3 Contributors to Labor Rate and Labor Rate Equation 

Summarized below are the four (4) contributors to labor costs used in this study: 

Direct Labor (DIR) is the mean manufacturing labor wage directly associated with 

fabricating, finishing and/or assembling a physical component or assembly. Examples 

falling into this labor classification would include injection mold press operators, die cast 

press operators, heat treat equipment operators, team/general assemblers, computer 

numerical controlled (CNC) machine operators, and stamping press operators. The 

median labor wage for each direct labor title is also included in the database; these values 

are treated as reference only. 

Indirect Labor (IND) is the manufacturing labor indirectly associated with making a 

physical component or assembly. Examples include material handling personnel, 

shipping and receiving personnel, quality control technicians, first-line supervisors, and 

manufacturing/process engineers. For a selected industry sector (such as injection 

molding, permanent casting, or metal stamping), an average ratio of indirect to direct 

labor costs can be derived from which the contribution of indirect labor ($/hour) can be 

calculated. 

This ratio is calculated as follows: 

1. An industry sector is chosen from the BLS, NAIC System. e.g., Plastics 

Product Manufacturing NAICS 326100. 

2. Within the selected industry sector, occupations are sorted (using SOC 

codes) into one (1) of the four (4) categories, Direct Labor, Indirect Labor, 

MRO Labor, or Other. 

3. For each category (excluding “Other”) a total cost/hour is calculated by 

summing up the population weighted cost per hour rates, for the SOC codes 

within each labor category. 

4. Dividing the total indirect labor costs by total direct labor costs, the 

industry sector ratio is calculated. 

5. When multiple industries employ the same type direct laborer, as defined 

by NAICS, a weighted average of indirect to direct is calculated using the 

top three (3) industries. 

Maintenance Repair and Other (MRO) is the labor required to repair and maintain 

manufacturing equipment and tools directly associated with manufacturing a given 

component or assembly. Examples falling into this labor classification include 

electricians, pipe fitters, millwrights, and on-site tool and die tradesmen. Similar to 

indirect labor, an average ratio of MRO to direct labor costs can be derived from which 

the contribution of MRO labor ($/hour) can be calculated. The same process used to 

calculate the indirect labor ratio is also used for the MRO ratio. 
7-14

Fringe (FR) is all the additional expenses a company must pay for an employee above 

and beyond their base wage. Examples of expenses captured as part of fringe include 

company medical and insurance benefits, pension/retirement benefits, government 

directed benefits, vacation and holiday benefits, shift premiums, training, etc. 

Fringe applies to all manufacturing employees. Therefore the contribution of fringe to 

the overall labor rate is based on a percentage of direct, indirect and MRO labor. Two (2) 

fringe rates are used: 52% for supplier manufacturing, and 160% for OEM 

manufacturing. The supplier manufacturing fringe rate is based on data aquired from the 

BLS; Employer Costs for Employee Compensation Historical Listings, March 2004 -

2009. Using the average 2007/2008 manufacturing sector numbers, an average fringe 

rate of 52% was calculated ([[$31.86-$20.95]/$20.95]*100), where average employee 

total compensation = $31.86/hour and wages and salaries = $20.95/hour). 

The OEM fringe rate was calculated the same way as the supplier fringe rate above. 

Taking the 2006/2007 average North American UAW OEM hourly wage and total 

compensation rate of $28.18 and $73.21 respectively, a rate of 160% was calculated. 

Additional details on these calculations can be found in the labor database. 

Taking the four (4) contributors of labor cost, the following labor rate equation for a 

manufacturing operation can be written: 

Labor Rate ($/Hour) = DIR+ IND + MRO + FR 

Where, 

IND = DIR * ILRR, where ILRR = Ratio of Indirect to Direct Overall Labor Costs 

MRO = DIR * MLRR, where MLRR = Ratio of MRO to Direct Overall Labor Costs 

FR = {DIR + IND + MRO}*%FR, where %FR is the fringe rate 

For example, to determine the applicable labor rate for a supplier injection molding 

facility: 

DIR = $15.15/hr (SOC 51-4072) 

ILRR = 66% 

MLRR = 23% 

%FR = 52% 

First indirect and MRO labor contributions are calculated: 
7-15

IND = $15.15 * 0.66 = $10.00/hr 

MRO = $15.15 * 0.23 = $3.48/hr 

Next Fringe is calculated as a percent of direct, indirect and MRO labor: 

Fringe = ($15.15 + $10.00 + $3.48) * 0.52 = $14.88/hr 

Lastly, the labor rate for injection molding is calculated by summing the four (4) 

contributors. 

Labor Rate = $15.15/hr + $10.00/hr + $3.48/hr + $14.88/hr = $43.52/hr 

In Figure 7-7, some additional examples of production occupations and corresponding 

total labor rates are shown. Similar calculations are made for every production 

occupation classification found in the Labor Database. 
7-16 

Figure 7-7: Labor Database Excerpt Showing Contributors to Total Labor Rate for Various Direct La
7-17 

7.4 Manufacturing Overhead Database 

7.4.1 Overview

The Manufacturing Overhead Database contains several manufacturing overhead rates 

(also sometimes referred to as burden rates, or simply burden) associated to various types 

of manufacturing equipment, that are required to manufacture automotive parts and 

vehicles. With material and labor costs, it forms the total manufacturing cost (TMC) to 

manufacture a component or assembly, accounting for workers, supervisors, managers, 

raw materials, purchased parts, production facilities, fabrication equipment, finishing 

equipment, assembly equipment, utilities, measurement and test equipment, handling 

equipment, office equipment, etc. Manufacturing equipment is typically one of the 

largest contributors to manufacturing overhead, and so manufacturing overhead rates are 

categorized according to primary manufacturing processes and the associated equipment 

as follows: 

1. The first tier of the Manufacturing Overhead Database is arranged by the primary 

manufacturing process groups (e.g., thermoplastic molding, thermoset molding, 

castings, forgings, stamping and forming, powder metal, machining, turning, etc.) 

2. The second tier subdivides the primary manufacturing process groups into primary 

processing equipment groups. For example the ‘turning group’ consists of several 

subgroups including some of the following: (1) CNC turning, auto bar fed, dual 

axis machining, (2) CNC turning, auto bar fed, quad axis machining, (3) double 

sided part, CNC turning, auto bar fed, dual axis machining, and (4) double sided 

part, CNC turning, auto bar fed, quad axis machining. 

3. The third and final tier of the database, increases the resolution of the primary 

processing equipment groups, and defines the applicable manufacturing overhead 

rates. The added resolution is typically based on part size and complexity and the 

need for particular models/versions of primary and secondary processing 

equipment. An excerpt from the Manufacturing Overhead Database is shown in 

Figure 7-8. In this example, the levels of complexity in CNC equipment are 

described and assigned an ‘Active Rate’, which is the burden cost-per-hour for the 

equipment. 
7-18 

 Figure 7-8: Manufacturing Overhead Database Excerpt Showing Standard 

Overhead Rates for CNC Turning 

Active Rate

2008

H. CNC Turning

H1. CNC Turning, Auto Bar Feed (BF), Dual Axis (DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over base assumptions.

1 SL-40BB, Bar Capacity=Ø178mm 1 Lathe Work Gauging Probe CNC Turning, MLS, BF, DA $32.88

2 Max Cutting Diameter = Ø648mm, Max Cutting 

Length =1118 mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

1 SL-30BB, Bar Capacity=Ø102mm 1 Lathe Work Gauging Probe CNC Turning, MS, BF, DA $27.08

2 Max Cutting Diameter = Ø432mm, Max Cutting 

Length =864mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

1 SL-20BB, Bar Capacity=Ø64mm 1 Lathe Work Gauging Probe CNC Turning, SMS, BF, DA $22.72

2 Max Cutting Diameter = Ø262mm, Max Cutting 

Length =508mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

1 SL-10BB, Bar Capacity=Ø51mm 1 Lathe Work Gauging Probe CNC Turning, SS, BF, DA $20.48

2 Max Cutting Diameter = Ø279mm, Max Cutting 

Length =356mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

H3.

1 THEO-TL-35BB, Bar Capacity=Ø178mm 1 Lathe Work Gauging Probe DS-CNC Turning, MLS, BF, 

DA $37.49

2 Max Cutting Diameter = Ø648mm, Max Cutting 

Length =1118 mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

1 TL-25 BB, Bar Capacity=Ø102mm 1 Lathe Work Gauging Probe DS-CNC Turning, MS, BF, $31.69

2 Max Cutting Diameter = Ø406mm, Max Cutting 

Length =864mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

1 TL-15BB, Bar Capacity=Ø64mm 1 Lathe Work Gauging Probe DS-CNC Turning, SMS, BF, 

DA $27.76

2 Max Cutting Diameter = Ø208mm, Max Cutting 

Length =445mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

1 THEO-TL-05BB, Bar Capacity=Ø51mm 1 Lathe Work Gauging Probe DS-CNC Turning, SS, BF, $25.52

2 Max Cutting Diameter = Ø279mm, Max Cutting 

Length =356mm 2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter

Double Sided (DS) Part, CNC Turning, Auto Bar Feed (BF), Dual Axis (DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over base 

assumptions.

H3.4

Double Sided Part, CNC Turning, Bar 

Fed, Machining in "C" and "Z" Axis 

Only, Small Size Parts

H3.3

Double Sided Part, CNC Turning, Bar 

Fed, Machining in "C" and "Z" Axis 

Only, Small-Medium Size Parts

H3.2

Double Sided Part, CNC Turning, Bar 

Fed, Machining in "C" and "Z" Axis 

Only, Medium Size Parts

H3.1

Double Sided Part, CNC Turning, Bar 

Fed, Machining in "C" and "Z" Axis 

Only, Medium-Large Size Parts

Burden 

Classification Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment

H1.1

CNC Turning, Bar Fed, Machining in 

"C" and "Z" Axis Only, Medium-Large 

Size Parts

H1.2

CNC Turning, Bar Fed, Machining in 

"C" and "Z" Axis Only, Medium Size 

Parts

H1.3

CNC Turning, Bar Fed, Machining in 

"C" and "Z" Axis Only, Small-Medium 

Size Parts

H1.4

CNC Turning, Bar Fed, Machining in 

"C" and "Z" Axis Only, Small Size 

Parts

A. Thermoplastic 

B. Theromset

C. Casting 

D. Forging

H. Turning

G. M achining

F . P o wder M etal J. Grinding

E. Stamping & 

Forming

M . P lating

R. OEM 

Assembly

S.

T . Q. OEM 

M achining

N. Washing

L. Heat Treat P . T 1/ T 2/ T 3 A ss'y

K. Balancing U.

V.

W. 

X.

Y. M iscellaneous

Z. 
7-19 

Manufacturing overhead rates for 2008 establish the baseline from which projected rates 

can be developed. A single Average Annual Adjustment Factor is used to for this 

purpose. 

7.4.2 Manufacturing Overhead Rate Contributors and Calculations

In this analysis burden is defined in terms of an “inclusion/exclusion” list as follows: 

Burden costs do not include: 

• manufacturing material costs 

• manufacturing labor costs 

o direct labor 

o indirect labor 

o maintenance repair and other (MRO) labor 

• mark-up 

o end-item scrap 

o corporate SG&A expenses 

o profit 

o ED&T/ R&D costs expenses 

• tooling (e.g. mold, dies, gauges, fixtures, dedicated pallets ) 

• packaging costs 

• shipping and handling costs 

Burden costs do include: 

• rented and leased equipment 

• primary and process support manufacturing equipment depreciation 

• plant office equipment depreciation 

• utilities expense 

• insurance (fire and general) 

• municipal taxes 

• plant floor space (equipment and plant offices) 

• maintenance of manufacturing equipment - non-labor 

• maintenance of manufacturing building - general, internal and external, parts, and 

labor 

• operating supplies 

• perishable and supplier-owned tooling 

• all other plant wages (excluding direct, indirect and MRO labor) 

• returnable dunnage maintenance 

• intra-company shipping costs 
7-20

As can be seen in the lists above, burden includes both fixed and variable costs. 

Generally, the largest contribution to the fixed burden costs are the investments 

associated with primary and process support equipment. The single largest contributor to 

the variable burden rate is typically utility usage. 

In general the average burden rate for a production facility is calculated by summing up 

the total burden costs for the facility for a pre-defined period. This value is then divided 

by either the total direct labor cost, the total direct labor hours, or the total machining 

hours. 

Since this cost analysis assumes that all production is in North America and at relatively 

high volumes, the standard quote assumption is that higher labor costs are offset by 

automation. With this assumption, there are considerably fewer direct labor hours versus 

machine hours, making a machine-based burden rate more applicable for this cost 

analysis. Thus all burden rates contained in the Manufacturing Overhead Database are 

considered machine based burden rates. 

Depending on the mix of equipment, processes, and product variation at a given 

manufacturing facility, a corporation may choose to apply either a flat rate approach or an 

activity based approach to burden rates. The flat rate approach assumes one burden rate 

for the entire manufacturing facility, regardless of the types of manufacturing processes 

employed. (For example, stamping, welding, and general assembly would all share a 

common burden rate). The activity based approach applies a unique burden rate to each 

core manufacturing activity or process which exists within the facility. For example, 

stamping welding, and general assembly would each be assigned a unique burden rate. 

For this cost analysis the majority of the costing is done using activity based burden rates. 

However, for a few components where there are some minor secondary operations 

performed, the flat rate approach is used for simplification. 

7.4.3 Acquiring Manufacturing Overhead Data 

Because there is very limited publicly available data on manufacturing overhead rates for 

the industry sectors included in this analysis, overhead rates have been developed from a 

combination of internal knowledge at FEV and Munro, supplier networks, miscellaneous 

publications, reverse costing exercises and “ground-up” manufacturing overhead 

calculations. 

For ground-up calculations, a generic “Manufacturing Overhead Calculator Template” 

was created. The template consists of eight (8) sections: A. General Manufacturing 

Overhead Information, B. Primary Process Equipment, C. Process Support Equipment, 

D. General Plant & Office Hardware/Equipment, E. Facilities Cost, F. Utilities, G. Plant 
7-21

Salaries, and H. Calculated Hourly Burden Rate. An example of the template can be 

found in Appendix E.4 illustrating the hourly burden rate calculation for a 500 ton (T) 

injection mold machine. To assist in the discussion of the various sections of the costing 

template, input and calculated values for this same example are captured below in 

parentheses. 

The General Manufacturing Overhead Information section, in addition to defining the 

burden title (Injection Molding, Medium Size and/or Moderate Complexity) and 

description (Injection Molding Station, 500T Press), also defines the equipment life 

expectancy (12 years), yearly operating capacity (4700 hours), operation efficiency 

(85%), equipment utilization (81.99%) and borrowing cost of money (8%). These input 

variables support many of the calculations made throughout the costing template. 

The Primary Process Equipment section (500T Horizontal Injection Molding Machine) 

calculates the annual expense ($53,139) associated with equipment depreciation over the 

defined life expectancy. A straight-line-depreciation method, with zero end of life value, 

is assumed for all equipment. Included in the cost of the base equipment are several 

factors including sales tax, freight, installation, insurance, maintenance-parts, etc. 

The Process Support Equipment section (e.g. Chiller, Dryer, Thermal Control UnitMold), similar to the primary process equipment section, calculates the annual expense 

($6,121) associated with process support equipment depreciation. 

The General Plant and Office Hardware/Equipment section assigns an annual 

contribution directed towards covering a portion of the miscellaneous plant & office 

hardware/equipment costs (e.g. millwright, electrician, and plumbing tool crib, 

production/quality communication, data tracking and storage, general material handling 

equipment, storage, shipping and receiving equipment, general quality lab equipment, 

office equipment). The contribution expense ($2,607) is calculated as a percent of the 

annual primary and process support equipment depreciation costs. 

The Facilities Cost section assigns a cost based on square footage utilization for the 

primary equipment ($4,807), process support equipment ($3,692), and general plant and 

office hardware/equipment ($6,374). The general plant and office hardware/equipment 

floor space allocation is a calculated percentage (default 75%) of the derived primary and 

process support equipment floor space. The expense per square foot is $11.50 and covers 

several cost categories including facility depreciation costs, property taxes, property 

insurance, general facility maintenance, general utilities, etc. 

The Utilities section calculates a utility expense per hour for both primary equipment 

($9.29/hour) and process support equipment ($3.51/hour) based on equipment utility 

usage specifications. Some of the utility categories covered in this section include: 

electricity at $0.10/Kw-hr., natural gas at $0.00664/cubic foot, and water at 
7-22

$0.001/gallon. General plant and office hardware/equipment utility expenses are covered 

as part of the facility cost addressed above (i.e., $11.50/square foot). 

The Plant Salary section estimates the contribution of manufacturing salaries (e.g. plant 

manager, production manager, quality assurance manager) assigned to the indirect 

participation of primary and process support equipment. An estimate is made on the 

average size of the manufacturing facility for this type of primary process equipment. 

There are six (6) established manufacturing facility sizes and corresponding salary 

payrolls to choose from; each has a calculated salary cost/square foot. Based on the 

combined square footage utilization of the primary, process support, and general plant 

and office equipment, an annual salary contribution cost is calculated ($6,625). 

The final section, Calculated Hourly Burden Rate, takes the calculated values from the 

previous sections and calculates the hourly burden rate in three (3) steps: (1) 100% 

efficiency and utilization ($30.54/hour), (2) user-defined efficiency with 100% utilization 

($35.12/hour), and (3) both user-defined efficiency and utilization ( $38.79/hour). 

The majority of primary process equipment groups (e.g. injection molding, aluminum die 

casting, forging, stamping and forming) in the manufacturing overhead database are 

broken into five (5) to ten (10) burden rate subcategories based on processing complexity 

and/or size, as discussed in the manufacturing overhead review. For any given category, 

there will often be a range of equipment sizes and associated burden rates which are 

averaged into a final burden rate. The goal of this averaging method is to keep the 

database compact while maintaining high costing resolution. 

In the example of the 500T injection molding press burden rate, the calculated rate 

($38.79) was averaged with three (3) other calculated rates (for 390T, 610T and 720T 

injection mold presses) into a final burden rate called “Injection Molding, Medium Size 

and/or Moderate Complexity”. The final calculated burden rate of $50.58/hour is used in 

applications requiring injection molding presses in the range of 400-800 tons. 

As discussed, multiple methods of arriving at burden rates are used within the cost 

analysis. Every attempt is made to acquire multiple data points for a given burden rate as 

a means of validating the rate. In some cases the validation is accomplished at the final 

rate level and in other cases multiple pieces of input data, used in the calculation of a rate, 

are acquired as a means of validation. 
7-23

7.5 Mark-up (Scrap, SG&A, Profit, ED&T) 

7.5.1 Overview 

All mark-up rates referenced throughout the cost analysis, for Tier 1 and Tier 2/3 

automotive suppliers, can be found in the Mark-up Database, except in those cases where 

unique component tolerances, performance requirements, or some other unique feature 

dictates a special rate. In cases where a mark-up rate is “flagged” within the costing 

worksheet, a note is included which describes the assumption differences justifying the 

modified rate. 

For this cost analysis study, four (4) mark-up sub-categories are used in determining an 

overall mark-up rate: (1) end-item scrap allowance, (2) SG&A expenses, (3) profit, and 

(4) ED&T/ R&D expenses. Additional details for each subcategory are discussed below. 

The layout of the Mark-up Database is similar to the Manufacturing Overhead Database 

in that the first tier of the Mark-up Database is arranged by the primary manufacturing 

process groups (e.g., thermoplastic processing, thermoset processing, casting, etc.). The 

second tier subdivides the primary manufacturing process groups into primary processing 

equipment groups (e.g., thermoplastic processing is subdivided into injection molding, 

blow or rotational molding, and pressure or vacuum form molding). The third and final 

tier of the database, increases the resolution of the primary processing equipment groups, 

and defines the applicable mark-up rates. Similar to the overhead manufacturing rates, 

size and complexity of the parts being manufactured will direct the process and 

equipment requirements, as well as investments, which in turn, will have a direct 

correlation to mark-up rates. 

For example, a small, low complexity Tier 2/Tier 3 injection molding facility will 

generally have less in-process scrap (as a result of defective parts and/or destructive 

testing), less corporate overhead, less investment risk, and less engineering, design and 

testing support than a large, high complexity Tier 2/Tier 3 injection molding facility, as 

illustrated in Figure 7-9. 
7-24 

Figure 7-9: Mark-up Database Excerpt Highlighting the Rate Differences ( End Item Scrap, SG&A, Profit, and ED&

Injection Molding, Based on Part Size and Complexity 
7-25 

As shown in the Figure 7-9, the Mark-up Database has a column for each category of 

mark-up, making it possible to modify each category independently or as a group. In 

addition, the mark-up rates for a particular supplier/OEM classification and/or primary 

processing equipment category can be modified independently. 

Mark-up rates for 2008 establish the reference baseline from which projected rates can be 

developed. A single average Annual Adjustment Factor is used to for this purpose. 

7.5.2 Mark-up Rate Contributors and Calculations

Mark-up, in general, is an added allowance to the Total Manufacturing Cost to cover enditem scrap, SG&A, profit and ED&T expenses. Below are some additional details on 

what is included in each mark-up category. 

End-Item Scrap Mark-up: is an added allowance to cover the projected manufacturing 

fall-out and/or rework costs associated with producing a particular component or 

assembly. In addition, any costs associated with in-process destructive testing of a 

component or assembly would also be covered by this allowance. As a starting point, 

scrap allowances were estimated to be between 0.3% and 0.7% of the TMC within each 

primary manufacturing processing group The actual assigned value, for each category, is 

an estimate based on size and complexity of the primary processing equipment as shown 

in Table 7-2. 

When published industry data or consultation with an industry expert produces more 

reliable estimates for scrap allowance associated with a generic manufacturing process 

(e.g. 5% for sand casting, investment casting), the Mark-up Database is updated 

accordingly. In cases where the manufacturing process is considered generic, but the 

component performance requirements drive a higher fall-out rate (e.g. 25% combined 

process fallout on turbocharger turbine wheels), then the scrap mark-up rate would only 

be adjusted in the Manufacturing Assumption Quote Summary (MAQS) worksheet. 

Selling, General, and Administrative (SG&A) Mark-up: is also referred to as corporate 

overhead or non-manufacturing overhead costs, and some of the more common cost 

elements of SG&A are as follows: 

• Non-manufacturing, corporate facilities (building, office equipment, utilities, 

maintenance expenses, etc.) 

• Corporate salaries (President, Chief Executive Officers, Chief Financial Officers, 

Vice Presidents, Directors, Corporate Manufacturing, Logistics, Purchasing, 

Accounting, Quality, Sales, etc.) 

• Insurance on non-manufacturing buildings and equipment 

• Legal and public relation expenses 

• Recall insurance and warranty expenses 
7-26

• Patent fees 

• Marketing and advertising expenses 

• Corporate travel expenses 

SG&A, like all mark-up rates, is an applied percentage to the Total Manufacturing Cost. 

The default rates for this cost analysis range between 6% to 7% within each of the 

primary processing groups. The actual values, as with the end-item scrap allowances, 

vary within these ranges based on the size and complexity of the part, which in turn is 

reflected in the size and complexity of the processing equipment as shown in Table 7-2. 

To support the estimated SG&A rates (which are based on generalized OEM data), 

SG&A values are extracted from publicly traded automotive supplier 10-K reports (Table 

7-1). 

Profit Mark-up: is the supplier’s or OEM’s reward for the investment risk associated with 

taking on a project. On average, the higher the investment risk, the larger the profit 

mark-up that is sought by a manufacturer. 

As part of the assumptions list made for this cost analysis, it is assumed that the 

technology being studied is mature from the development and competition standpoint. 

These assumptions are reflected in the conservative profit mark-up rates which range 

from 4% to 8% of the Total Manufacturing Cost. The profit mark-up ranges selected 

from this cost analysis are based on generalized historical data from OEMs and suppliers. 

As detailed with the preceding mark-up rates, the actual assigned percentage is based on 

the supplier processing equipment size and complexity capabilities (Table 7-2). 

ED&T Mark-up: the ED&T used for this cost analysis is a combination of “Traditional 

ED&T” plus R&D mark-up. 

Traditional ED&T may be defined as the engineering, design and testing activities 

required to take an "implementation ready" technology and integrate it into a specific 

vehicle application. The ED&T calculation is typically more straight-forward because 

the tasks are predefined. R&D, defined as the cost of the research and development 

activities required to create a new (or enhance an existing) component/system 

technology, is often independent of a specific vehicle application. In contrast to ED&T, 

pure R&D costs are very difficult to predict and are very risky from an OEM and 

suppliers perspective, in that these costs may or may not result in a profitable outcome. 

For many automotive suppliers and OEMs, traditional ED&T and R&D are combined 

into one (1) cost center. For this cost analysis, the same methodology has been adopted, 

creating a combined traditional ED&T and R&D mark-up rate simply referred to as 

ED&T. 
7-27

Based on the assumption stated above for this cost analysis (technology is mature from 

the product development and competition point-of-view), a ED&T mark-up range 

between 0% to 6% has been selected. The selected range is based on a combination of 

publications examining ED&T mark-up rates in the automotive industry, available 10K 

reports, and EPA’s Indirect Cost Multiplier report. Table 7-1 provides some examples of 

Tier 1 automotive supplier SG&A and ED&T/R&D rates. These rates are based on 

world wide operations including automotive and non-automotive components. 

Table 7-1: Tier 1 Published SG&A and ED&T/R&D Rates for 2007 and 2008 

SG&A ED&T/R&D

Corporation 2008 2007 2008 2007

Dana Holding Corp 4.2% 4.2% 2.4% 2.2%

Wescast Industries Inc. 6.5% 7.2% 2.4% 2.0%

Honeywell Internationational Inc 13.8% 13.2% 4.2% 4.2%

Delphi Corp 10.5% 9.0% 8.1% 7.2%

Federal Mogul Corp 8.8% 9.4% 2.5% 2.6%

American Axle and Manufacturing 4.8% 3.8% 4.0% 2.5% 

Source: 2008 Company Annual Financial Reports 

Royalty fees, as the result of employing intellectual property, are also captured in the 

ED&T mark-up section. When such cases exist, separate lines in the Manufacturing 

Assumption & Quote Summary (MAQS) worksheet are used to capture these costs. 

These costs are in addition to the standard ED&T rates. The calculation of the royalty 

fees are on a case by case basis and information regarding the calculation of each fee can 

be found in the individual MAQS worksheets where applicable. 

As part of the costing assumptions, intellectual property is always treated as though it is 

purchased from a second entity. 

See Table 7-2 for applicable mark-up rates based on the supplier processing equipment 

size and complexity capabilities. 
7-28

Table 7-2: Standard Mark-up Rates Applied to Tier 1 and Tier 2/3 Suppliers Based on 

Size and Complexity Ratings 

Primary Manufacturing Equipment Group 

End Item 

Scrap 

Mark-up 

SG&A 

Mark-up 

Profit 

Mark-up 

ED&T 

Mark-up 

Total 

Mark-up 

 

Tier 2 /3 – Large Size, High Complexity, 0.7% 7.0% 8.0% 2.0% 17.7% 

Tier 2 /3 – Medium Size, Moderate 

Complexity, 0.5% 6.5% 6.0% 1.0% 14.0% 

Tier 2 /3 – Small Size, Low Complexity 0.3% 6.0% 4.0% 0.0% 10.3% 

 

Tier 1 Complete System/Subsystem Supplier 

(System/Subsystem Integrator) 0.7% 7.0% 8.0% 6.0% 21.7% 

T1 High Complexity Component Supplier 0.7% 7.0% 8.0% 4.0% 19.7% 

T1 Moderate Complexity Component 

Supplier 0.5% 6.5% 6.0% 2.5% 15.5% 

T1 Low Complexity Component Supplier 0.3% 6.0% 4.0% 1.0% 11.3% 

The following additional points should be noted: 

For Tier 2/Tier 3 (T2/T3) suppliers, the same level of mark-up is applied regardless of the 

primary manufacturing process group and primary manufacturing equipment group 

involved. For example a T2/T3, large, high complexity thermoplastic injection molding 

process will have the same mark-up rates as a T2/T3, large, high complexity, stamping 

and forming fine blanking process; it is size and complexity capabilities which produce 

the different mark-up rates within the T2/T3 supplier’s classifications. 

• In reference to the item above, these are standard or base rates. If one of the 

primary manufacturing process groups and/or equipment groups requires a higher 

scrap, SG&A, profit and/or ED&T rate, the Mark-up Database is adjusted 

accordingly. 

• The Tier 1 (T1) mark-up classification system is based on a component, 

assembly, or system complexity ranking. For example a supplier who is 

manufacturing complete transmissions for an OEM would charge a total mark-up 

rate of 21.7% on the Total Manufacturing Costs versus the Supplier who provides 

an oil pan directly to the OEM would only receive 11.3% in mark-up. 
7-29

• All value-added operations, in addition to final assembly performed by a T1 

supplier (injection molding, casting, stamping, etc.), receive the mark-up rate 

defined by their complexity rating. 

7.5.3 Assigning Mark-up Rates

The three (3) primary steps to matching mark-up rates to a given component/assembly 

are as follows: 

Step 1. Primary manufacturing process and equipment groupings are pre-selected 

as part of the process to identify the manufacturing overhead rate. 

Step 2. Manufacturing facilities are identified as OEM, T1 or T2/T3 (this 

identification process is discussed in more detail in the Manufacturing Assumption 

& Quote Summary worksheet section). 

Step 3. The best-fit mark-up rate is selected based on the size and complexity of 

the part, which in turn is reflected in the size and complexity of the processing 

equipment. Note that size and complexity are considered as independent 

parameters when reviewing a component and the equipment capabilities (with 

priority typically given to ‘complexity’) 

Table 7-3 is an example of mark-up rate classifications based on size and complexity 

combinations for some typical stampings, castings, and injection molded parts. In 

addition, other attributes which are not included in the naming convention (such as 

component function and performance) are also considered when assigning mark-up rates. 
7-30

Table 7-3: Generic Mark-Up Rate Classification Based on Component Size and 

Complexity 

Size 

Attribute 

Complexity Attribute Mark-Up Rate Classification 

Large High Large Size, High Complexity 

Medium High Large Size, High Complexity 

Small High Large Size, High Complexity 

Large Moderate Large Size, High Complexity 

Medium Moderate Medium Size, Moderate Complexity 

Small Moderate Medium Size, Moderate Complexity 

Large Low Medium Size, Moderate Complexity 

Medium Low Small Size, Low Complexity 

Small Low Small Size, Low Complexity 

7.6 Packaging Database 

7.6.1 Overview

The Packaging Database contains standardized packaging options available for 

developing packaging costs for components and assemblies. In the cost analysis only 

packaging costs required to transport a component/assembly from a Tier 1 to an OEM 

facility (or one facility to another at the same OEM) are calculated in detail. For Tier 2/3 

suppliers of high- and low-impact components, as well as purchased parts, the Tier 1 

mark-up is estimated to cover the packaging as well as shipping expenses. Tier 1 markup on incoming Tier 2/3 parts and purchase parts are discussed in more detail in Section 

8. 

All core packaging items (containers, pallets, totes, etc.) referenced in the database are 

considered returnable dunnage. Internal packaging (tier pads, dividers, formed trays, 

etc.) are also considered returnable with the exception of a few items that are expendable. 

The cost to clean and maintain returnable dunnage is assumed to be covered by the 

manufacturing overhead rate. 
7-31

7.6.2 Types of Packaging and Selection Process

Packaging options in the database are limited to a few standard types and sizes to 

minimize complexity. In general, everything is tailored towards fitting onto a standard 

automotive pallet (as specified by the Automotive Industry Action Group), which has 

exterior dimensions of 48 by 45 inches and a base height assumption of 34 inches 

(although other standard sizes exist in 25, 33 39, 42, 48, and 50 inches in height). A 

standard transport trailer height of 106” is used as the guideline for overall packaging 

height. 

When initially trying to package a component, three (3) typical packaging options are 

considered: 

• standard 48 by 45 by 34-inch palletized container (with tier pads and 

dividers) 

• 48 by 45-inch base pallet with stacked 21.5 by 15 by 12.5-inch totes (48 

totes max – and note that totes can have specialized tier pads, dividers, etc.) 

• 48 by 45-inch base pallet with vacuum formed dividers strapped together 

Considering component attributes such as weight, size, shape, fragility, and cleanliness, 

one (1) of the packaging options above are selected, along with an internal dunnage 

scheme. If it is deemed impractical to package the component within one (1) of the 

primary options, a new package style is created and added to the Packaging Database. 

Once the primary packaging type and associated internal dunnage are selected for a 

component, the assumptions along with the costs are entered into a Manufacturing 

Assumption Quote Summary (MAQS) worksheet. In the MAQS worksheet, packaging 

costs along with volume assumptions, pack densities, stock turn-over times, program life, 

packaging life, and interest expenses are used to calculate a cost-per-part for packaging. 

Section 9 provides more details on the calculation of packaging costs. 

7.6.3 Support for Costs in Packaging Database

Primary pallet and container costs are acquired from either Tier 1 automotive suppliers or 

from container vendors. In some cases, scaling within container groups is performed to 

quantify the pricing for slightly larger or smaller containers within the same family. 

Internal dunnage costs are acquired from either Tier 1 automotive suppliers or calculated 

based on standard material and processing estimates. When tooling costs are required for 

packaging, the value of that tooling is added to the total pallet container piece cost, as 

calculated in the MAQS worksheets. The total value is then amortized to calculate a 

cost-per-part for packaging.
8-1 

8 Shipping Costs 

In the cost analysis, shipping costs are accounted for by one of three factors: Indirect 

Cost multiplier, total mark-up allowance, or manufacturing overhead. Further shipping 

costs, with the exception of inner company transportation, are always considered freight 

on board (FOB) the shipper’s dock. Below are the four (4) shipping scenarios 

encountered in the cost analysis and how each case is handled. 

The first two (2) cases, OEM and supplier inner company transportation, shipping costs 

are accounted for as part of the manufacturing overhead rate. It is assumed that the OEM 

or supplier would either have their own transportation equipment and/or subcontract this 

service out. In either case the expense is binned to manufacturing overhead. 

The third case is Tier 1 shipments to an OEM facility. As stated above the shipments are 

FOB the shipper’s dock and thus the OEM is responsible for the shipping expense. In this 

case the Indirect Cost multiplier is assumed to cover the OEM’s expense to have all parts 

delivered to the applicable OEM manufacturing facilities. 

The final case is Tier 2/3 shipments to the Tier 1 facility. Generally, the Tier 1 supplier is 

allowed a mark-up on incoming purchased parts from Tier 2/3 suppliers. The mark-up 

covers many costs including the shipping expenses to have the part delivered onto the 

Tier 1 supplier’s dock. Further, the mark-up can either be a separate mark-up only 

applied to incoming purchased parts, or accounted for by the mark-up applied to the 

TMCs. In the former, the purchase part content would not be included in the final markup calculation (i.e., Mark-up = (TMC -Purchase Parts cost) x Applicable Mark-up Rate). 

For this cost analysis, the latter case is chosen using the same mark-up rate for all Tier 1 

value-added manufacturing as well as all incoming purchase parts. 
9-1 

9 Manufacturing Assumption and Quote Summary Worksheet 

9.1 Overview 

The Manufacturing Assumption and Quote Summary (MAQS) worksheet is the 

document used in the cost analysis process to compile all the known cost data, add any 

remaining cost parameters, and calculate a final unit cost. All key manufacturing cost 

information can be viewed in the MAQS worksheet for any component or assembly. 

Additional details on the information which flows into, and out of the MAQS worksheet 

are discussed in more detail below. Section 11 discusses how MAQS worksheets are 

uploaded into subsystem and system summary templates to calculate the net 

component/assembly cost impact to the OEM. 

The fundamental objective of the MAQS worksheet is similar to a standard quoting 

template used by the automotive industry. However the format has been revised to 

capture additional quote details and manufacturing assumptions, improve on transparency 

by breaking out all major cost elements, and accommodate variable data inputs for the 

purpose of sensitivity assessments. These features are discussed in more detail below. 

For a given case study, all Tier 1 or OEM assemblies, identified in the CBOM as 

requiring cost analysis, will have a link to a MAQS worksheet. In some cases where high 

value final assembly Tier 2/3 parts are shipped to a Tier 1 supplier, a separate MAQS 

worksheet is created for greater transparency. These T2/3 MAQS worksheets are linked 

to T1/OEM MAQS worksheets, which in turn are referenced back to the CBOM. 

9.2 Main Sections of Manufacturing Assumption and Quote Summary 

Worksheet 

At the top of every MAQS worksheet is an information header (Section A) which 

captures the basic project details along with the primary quote assumptions. The project 

detail section references the MAQS worksheet back to the applicable CBOM. The 

primary quote assumption section provides the basic information needed to put together a 

quote for a component/assembly. Some of the parameters in the quote assumption 

section are automatically referenced/linked throughout the MAQS worksheet such as 

capacity planning volumes, product life span, and OEM/T1 classification. The remaining 

parameters in this section including facility locations, shipping methods, packing 

specifications, and component quote level are manually considered for certain 

calculations. Included in Appendix F.1 is a sample MAQS worksheet identifying all the 

major sections. 

Two (2) parameters above whose functions perhaps are not so evident from their names 

are the “OEM/T1 classification” and “component quote level”. 
9-2

The “OEM/T1 classification” parameter addresses who is taking the lead on 

manufacturing the end-item component, the OEM or Tier 1 supplier. In addition, the 

OEM or Tier 1 level, defined by size, complexity, and expertise level is also captured. 

The value entered into the cell is linked to the Mark-up Database, which will up-load the 

corresponding mark-up values from the database into the MAQS worksheet. For 

example if “T1 High Assembly Complexity” is typed into the input cell, the following 

values for mark-up are pulled into the worksheet: Scrap = 0.70%, SG&A = 7%, Profit = 

8.0% and ED&T = 4%. These rates are then multiplied by the TMC at the bottom of the 

MAQS worksheet to calculate the applied mark-up as shown in Figure 9-1. 

The process for selecting the classification of the lead manufacturing site (OEM or T1) 

and corresponding complexity (e.g. High Assembly Complexity, Moderate Assembly 

Complexity, Low Assembly Complexity) is based on the team’s knowledge of existing 

value chains for same or similar type components. 

 

Figure 9-1: Excerpt Illustrating Automated Link between OEM/T1 Classification Input 

in MAQS Worksheet and the Corresponding Mark-up Percentages Uploaded from the 

Mark-up Database 

The “component quote level” identifies what level of detail is captured in the MAQS 

worksheet for a particular component/assembly, full quote, modification quote, or 

differential quote. When the “full quote” box is checked off, it indicates all 

manufacturing costs are captured for the component/assembly. When the “modification 

quote” box is checked off, it indicates only the changed portion of the 

component/assembly, has been quoted. A differential quote is similar to a modification 

quote with the exception that information from both technology configurations, is 

TMC 
9-3

brought into the same MAQS worksheet, and a differential analysis is conducted on the 

input cost attributes versus the output cost attributes. For example, if two (2) engine 

cylinder heads are being compared for cost, each head can have its’ differences quoted in 

a separate MAQS worksheet (modification quote) and the total cost outputs for each can 

be subtracted to acquire the differential cost. Alternatively in a single MAQS worksheet 

the cost driving attributes for the differences between the head’s (e.g., weight, material 

type, machining time, heat treat processes, etc.) can be offset, and the differential cost 

calculated in a single worksheet. The differential quote method is typically employed 

with those components with low differential cost impact to help minimize the number of 

MAQS worksheets being generated. 

From left to right, the MAQS worksheet is broken into two (2) main sections as the name 

suggests, a quote summary (Section B) and manufacturing assumption section (Section 

D). The manufacturing assumption section, positioned to the right of the quote summary 

section, is where the additional assumptions and calculations are made to convert the 

serial processing operations from Lean Design® into mass production operations. 

Calculations made in this section are automatically loaded into the quote summary 

section. The quote summary section, utilizes this data, along with other costing database 

data, to calculate the total cost for each defined operation in the MAQS worksheet. 

Note “defined operations” are all the value-added operations required to make a 

component or assembly. For example, a high pressure fuel injector may have twenty (20) 

base level components which all need to be assembled together. To manufacture one (1) 

of the base level components there may be as many as two (2) or three (3) value-added 

process operations (e.g., cast, heat treat, machine). In the MAQS worksheet each of these 

process operations has an individual line summarizing the manufacturing assumptions 

and costs for the defined operation. For a case with two (2) defined operations per base 

level component, plus two (2) subassembly and final assembly operations, there could be 

as many as forty (40) defined operations detailed out in the MAQS worksheet. For ease 

of viewing all the costs associated with a part, with multiple value-added operations, the 

operations are grouped together in the MAQS worksheet. 

Commodity based purchased parts are also included as a separate line code in the MAQS 

worksheet. Although there are no supporting manufacturing assumptions and/or 

calculations required since the costs are provided as total costs. 

From top to bottom, the MAQS worksheet is divided into four (4) quoting levels in which 

both the value-added operations and commodity based purchase parts are grouped: (1) 

Tier 1 Supplier or OEM Processing and Assembly, (2) Purchase Part – High Impact 

Items, (3) Purchase Part – Low Impact Items, and (4) Purchase Part – Commodity. Each 

quoting level has different rules relative to what cost elements are applicable, how cost 

elements are binned, and how they are calculated. 
9-4

Items listed in the Tier 1 Supplier or OEM Processing and Assembly section are all the 

assembly and subassembly manufacturing operations assumed to be performed at the 

main OEM or T1 manufacturing facility. Included in manufacturing operations, would 

be any on-line attribute and/or variable product engineering characteristic checks. For 

this quote level full detailed cost analysis is performed, with the exception of mark-up 

which is applied to the TMC at the bottom of the worksheet. 

Purchase Part – High Impact Items include all the operations assumed to be performed 

at Tier 2/3 (T2/3) supplier facilities and/or T1 internal supporting facilities. For this 

quote level, detailed cost analysis is performed including mark-up calculations for those 

components/operations considered to be supplied by T2/3 facilities. T1 internal 

supporting facilities included in this category do not include mark-up calculations. As 

mentioned above, the T1 mark-up (for main and supporting facilities), is applied to the 

TMC at the bottom of the worksheet. 

Purchase Part – Low Impact Items are for higher priced commodity based items which 

need to have their manufacturing cost elements broken out and presented in the MAQS 

sheet similar to high impact purchase parts. If not, the material cost group in the MAQS 

worksheet may become distorted since commodity based purchase part costs are binned 

to material costs. The cost estimating methodology used is basically a reverse costing 

process, where the total cost is known and estimates are required to divide the costs into 

material, labor, burden and mark-up. This level of quoting was not frequently used in the 

first case study (#0101). 

Purchase Part – Commodity parts are represented in the MAQS worksheet as a single 

cost and are binned to material costs. 

At the bottom of the MAQS worksheet (Section F), all the value-added operations and 

commodity based purchase part costs, recorded in the four (4) quote levels, are 

automatically added together to obtain the TMC. The applicable mark-up rates based on 

the T1 or OEM classification recorded in the MAQS header are then multiplied by the 

TMC to obtain the mark-up contribution. Adding the TMC and mark-up contribution 

together a subtotal unit cost is calculated. 

Important to note is that throughout the MAQS worksheet, all seven (7) cost element 

categories (material, labor, burden, scrap, SG&A, profit, and ED&T) are maintained in 

the analysis. Section C, MAQS breakout calculator, which resides between the quote 

summary and manufacturing assumption sections, exists primarily for this function. 

The last major section of the MAQS worksheet is the packaging calculation, Section E. 

In this section of the MAQS worksheet a packaging cost contribution is calculated for 

each part based on packaging requirements, pack densities, volume assumptions, stock 

and transit lead times, etc. 
9-5

The sample packaging calculation (Figure 9-2) is taken from the high pressure fuel 

injector MAQS worksheet, Case Study #N0101. In this example, six (6) weeks (which is 

the default value) of packaging is required to support inventory and transit lead times. 

This equates to packaging for 229,787 parts, over the six (6) weeks, based off the weekly 

capacity planning rates. There are 9,072 pieces per pallet at a packaging hardware cost of 

$4180 per pallet (container and internal dunnage costs are from the Packaging Database). 

From the above information, twenty (26) pallet sets are required @ $4180/set equaling a 

total of $108,680 in packaging costs. Packaging is estimated to last sixty (60) months. 

Thus applying the amortization formula based on sixty (60) months, 5% interest, and 9M 

parts/ 60 months yields $0.014/part. This cost is added to the subtotal unit cost (TMC + 

mark-up) to obtain the Total Unit Cost. 

Note in this case both the container and dunnage are assumed returnable. Thus the 

bottom section of the packaging calculator is not used. 

Figure 9-2: Example of Packaging Cost Calculation for a High Pressure Fuel Injector 

9.3 Manufacturing Assumption and Quote Summary Detail Review 

Although simple in function, the MAQS worksheet appears rather complex due to the 

amount of information imported, referenced, analyzed, and exported. To help describe 

this information flow into and out of the MAQS worksheet, as well as the internal 

interactions taking place, a detailed reference table has been created.

In Appendix F.1, the main tasks for each section of the MAQS worksheet have been 

listed, along with the input sources, reference sources and output sources of information 

and data exchange associated with each task. In addition, key sources of interaction and 

data exchanges have been identified with special text formatting to help highlight these 

key interaction sources. For example two (2) of the major sources of data into the MAQS 

worksheet come from Lean Design® process maps/exports and databases (five (5) 

databases in total). Thus, both these sources are highlighted through the table. Lastly, in 

the task description column, the word “Enter” or “Automatically” have been highlighted 
9-6

to give the reader a sense of how much data is manually entered versus automatically 

loaded for each MAQS worksheet. 

Note, revisions were made to the MAQS worksheet template as the cost study analysis 

progressed. As such, the information shown in Appendix F.1, MAQS Worksheet Task 

Reference Guide and accompanying MAQS worksheet template, will exist at a higher 

revision level than a few of the case study MAQS worksheets found in Appendix G.1. 

Only components which required the latest revision level MAQS template features were 

updated during the first cost analysis.
10-1 

10 Marketplace Validation 

Marketplace validation is the process by which individual parts, components and/or 

assemblies are cross-checked with costing data developed by entities and processes 

external to the team responsible for the cost analysis. This process occurs at all stages of 

the cost analysis; special emphasis is placed on cross-checking in-process costs (e.g. 

material costs, material selection, labor costs, manufacturing overhead costs, scrap rates, 

and individual component costs within an assembly). 

In-process cost validation occurs when a preliminary cost has been developed for a 

particular part within an assembly, and the cost is significantly higher or lower than 

expected based on the team’s technical knowledge, or on pricing from similar 

components. In this circumstance the cost analysis team would first revisit the costs, 

drawing in part/process-specific internal expertise and checking surrogate parts from 

previously costed bills of materials where available. If the discrepancy is still unresolved, 

the team would rely on automotive supplier networks, industry experts, and/or publicly 

available publications to validate the cost assumptions, making changes where warranted. 

Cross-checking on final assembly costs (e.g. turbochargers, direct injectors, high pressure 

fuel pumps) also occurs within the scope of the cost analysis, mainly as a “big picture” 

check. In general cross-checking final assembly costs are typically achieved through 

solicitation of industry experts. The depth of cross-checking ranges from simple 

comparison of cost data on surrogate assemblies to full Manufacturing Assumption and 

Quote Summary (MAQS) worksheet reviews. 
11-1 

11 Cost Model Analysis Templates 

11.1 Subsystem Cost Model Analysis Templates 

The Subsystem Cost Model Analysis Template (CMAT) is the document used to display 

and roll-up all the costs associated with a subsystem (fuel induction, air induction, 

exhaust, etc.) as defined by the CBOM. All parts identified, within the applicable 

subsystem of the CBOM, as requiring cost analysis, are entered into the CMAT. Also 

both the base and new technology configurations are included in the same CMAT to 

facilitate the differential cost analysis. 

The cost inputs for the Subsystem CMAT are the MAQS worksheets. As discussed 

previously, generally every component and assembly identified in the CBOM, as 

requiring cost analysis will have a MAQS worksheet. However, there are a few key 

exceptions to this rule, listed below, worth pointing out. 

1. Because the basis of the analysis is a differential analysis, the base technology 

configuration is assumed “Zero Cost” and everything is quoted as a differential to 

this zero baseline. Thus in many case studies there are very few MAQS 

worksheets for the baseline configuration. Note that in the CMAT, “$ 0” or “$ -” 

indicates that no MAQS worksheets exists. 

2. In those cases where the baseline configuration has identified differences requiring 

costing, two (2) potential paths are possible. 

a. A Full or Modified Quote level MAQS worksheet (pending situation) is 

created for both the new and base technology components and/or 

assemblies, and the totals are subtracted out in the CMAT. 

b. A Differential Quote level MAQS worksheet is created where both the 

baseline and new technology components or assemblies are pulled into 

the same MAQS worksheet for differential cost analysis. In this case 

the costs are binned to either the base or new technology configuration 

(case dependent) and the technology configuration showing zero costs is 

highlighted yellow (i.e., “$ 0” or “$ - ”) in the CMAT. 

The MAQS worksheets are automatically linked to the CMAT templates to facilitate 

automatic updating for assumption changes and/or sensitivity studies. This includes 

uploading all eight (8) unit cost elements including packaging. Figure 11-1 and Figure 

11-2 are samples excerpts of the CMAT taken from the Fuel Induction Subsystem, Case 

Study #0101 (Base 2.4L I4, Naturally Aspirated, Port Fuel Injected (PFI) downsized to a 

new 1.6L, I4 Turbo, Direct Injection (DI). Included in Figure 11-1, is an overlay of the 

Unit Cost Summary section, taken from the MAQS worksheet for the high pressure fuel 

Pump, highlighting the link between the documents. For this particular Fuel Induction 

Subsystem example, the Net Component Assembly Cost Impact to the OEM is $148.18, 

for the new technology configuration, and $40.84 for the base technology configuration. 
11-2

Thus $107.34 ($148.18-$40.84) is the pre-estimated cost impact to add DI over PFI. Preestimated indicating that there are other potentially cost factors for adding DI which are 

not included in the Fuel Induction Subsystem classification. For example additional 

machining of the cylinder head for mounting the injectors would be an added cost 

addressed in the Head Subsystem. 
11-3 

Figure 11-1: Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem Cost Roll Up 

Subsystem - New Technology Configuration - Case Study #N0101 

Example showing Section F of the MAQS workfor the high pressure fuel pump, uploading subsystem CMAT. 
11-4

Figure 11-2: Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem Cost Roll Up 

Subsystem - Base Technology Package - Case Study #B0101
11-5 

11.2 System Cost Model Analysis Template 

The System CMAT, similar in function to the Subsystem CMAT, is the document used to 

display and roll-up all the subsystem costs associated within a system, as defined by the 

Comparison Bill of Materials. Within the scope of this cost analysis, the System CMAT 

provides the bottom line unit cost, between the base and new technology configurations 

under evaluation. 

As evident in Figure 11-3, the same level of cost detail is maintained throughout all 

documents providing optimal transparency up to the concluding cost worksheet. In 

addition, all Subsystem CMAT totals are linked directly to the System CMAT supporting 

automatic updates due to assumption changes and/or sensitivity studies. 
11-6 

Figure 11-3: Excerpt from System Cost Model Analysis Template Illustrating the Incrmental Subyst

Case Study #0101 - 2.4L I4, 16 Valve, DOHC, NA, PFI downsized to 1.6L I4, DOHC, Turb
12-1 

12 Operating and End-of-Life Costs 

Some of the technologies being analyzed may involve additional maintenance or a 

change in existing maintenance. Some may also involve additional vehicle scrappage 

costs or salvage value. These incremental costs and savings are evaluated and presented 

separately from the new vehicle unit costs. 

The maintenance and end-of-life cost calculations are performed on a case basis, using 

methodologies developed and documented specifically for the relevant technology case. 

The general methodology for maintenance calculations is the following: 

1. Identify a new or altered maintenance practice based on owner’s manuals, service 

instructions, and the team’s engineering knowledge of how the technology affects 

vehicle operation. 

2. Calculate the differential cost of the identified maintenance practice. 

3. Calculate the number of corresponding maintenance cycles over the expected 

service life of the vehicle. 

4. Calculate an incremental cost (or savings) per year and a net present value of the 

cumulative costs. 

A similar approach is used for the differential salvage value and disposal costs. The 

#0101 case study documented in this report has identified no new or modified 

maintenance or end-of-life costs. 
13-1 

13 Results for Case Study #0101 

Using the established study methodology detailed in the previous sections, the first cost 

study analysis was conducted: stoichiometric, gasoline direct injection (GDI) with 

turbocharging on a downsized I4 engine, compared to an equivalent conventional I4 

engine. The hardware chosen to represent the new technology configuration was the 2007 

Mini Cooper S, 1.6L I4, four (4) valve, dual overhead cam, turbocharged, direct injection 

engine (172 hp). The engine selected to represent the baseline configuration was the 

2007 Chrysler GEMA 2.4L I4, four (4) valve, dual overhead cam, naturally aspirated, 

port fuel injected engine (173 hp). 

Figure 13-1 is an excerpt from the System CMAT showing the incremental cost impact 

for each subsystem for Case Study #0101. For Case Study #0101, condensed versions of 

all supporting MAQS worksheets can be found in Appendix G.1. In addition the 

Subsystem CMATs and the System CMAT may be found in Appendix H.1 and H.2 

respectively. Table 13-1, captures some of the basic cost analysis assumptions made for 

this first case study (#0101). 

Because many of the documents referenced within this report are too large to be shown in 

their entirety (e.g. MAQS worksheets, CMATs, Costing Databases), electronic copies 

can be accessed at http://www.epa.gov/otaq/. 
13-2

Figure 13-1: System Cost Model Analysis Template Illustrating the Incremental 

Subsytem Costs Roll Up for I4, Turbo, GDI Downsizing, Case Study #0101 
13-3

 Table 13-1: Summary of Cost Analysis Assumptions for Case Study #0101 

Description Case Study Assumption 

Annual Volume 450,000 units 

Supplier Manufacturing Locations North America 

OEM Manufacturing Locations North America 

Manufacturing Cost Structure: 

(e.g. Material Costs, Labor Rates, 

Manufacturing Overhead Rates) 

2008 production year rates 

Supplier Mark-up Rate Structure: 2008 production year rates, 

based on mature technology assumptions 

Manufacturing Process and Operation 

Considerations Based on standard/mainstream industrial practices 

Intellectual Property Cost 

Considerations 

No special cases of intellectual property were identified 

and costed within the analysis. 

Cost analysis identified and assigned 

costs to neighboring systems as a 

result of new technology adaptation. 

No neighboring system (e.g. Engine Mounting, NVH 

Packages) upgrades were considered in analysis. 

Assumed that the engine mounts and NVH packages were 

of reasonable quality for the PFI engine. As such, no 

changes would be required for the adaptation of turbo DI 

Operating and End-of Life Costs No new, or modified, maintenance or end-of-life costs, 

were identified in this analysis. 

Material Cost Reductions (MCRs) on 

analyzed hardware. 

Potential MCRs were identified and evaluated, but not 

found to be of great significance to the incremental cost. 

As representative hardware is acquired, the potential exists 

to create MCR costing scenarios based on the initial cost 

analysis work. 

New Technology Advances (NTAs) on 

analyzed hardware 

 Potential NTAs were identified and evaluated, but not 

found to be of great significance to the incremental cost. 

As representative hardware is acquired, the potential exists 

to create NTA costing scenarios based on the initial cost 

analysis work. 

Costs elements not handle within the 

scope of this cost analysis. 

Several cost elements (e.g. OEM mark-up, vehicle and 

system engineering, design and testing costs, dedicated 

production tooling costs) are handled through the 

application of an Indirect Cost Multiplier. See EPA report 

EPA-420-R-09-003, February 2009, “Automobile Industry 

Retail Price Equivalent and Indirect Cost Multipliers” for 

additional details. 
14-1 

14 Sensitivity Analysis 

For this case study, it was necessary to understand how sensitive the incremental unit cost 

impact ($537.70) was to any future changes in the cost of materials, labor, burden or 

mark-up. The following scenarios were modeled relative to 2008 dollars: supplier and 

OEM labor cost -20%; OEM labor rate fringe contribution reduced from 160% to 52% 

(matching supplier rate); burden cost -20%; material cost +/- 20%; mark-up +/- 20%. 

Given the clear trends in North American manufacturing, only declines were considered 

for the labor and burden rates within this sensitivity analysis. The percent change in cost 

for each of these categories was modeled independently, and the results for each scenario 

are shown in Table 14-1. 

Table 14-1: Cost Model Sensitivity Study Results 

Model Description Net Component /Assembly 

Cost Impact to OEM 

Baseline, Case Study #0101 $537.70 

20% average decrease in labor rates $520.16 (-3%) 

OEM fringe reduced from 160% to 52% $530.28 (-1%) 

20% average decrease in burden rates $498.59 (-7%) 

20% average decrease in raw material costs(1) $493.94 (-8%) 

20% average increase in raw material costs(1) $581.46 (+8%) 

20% average decrease in mark-up rates $519.47 (-3%) 

20% average increase in mark-up rates 555.93 (+3%) 

1 Both raw material and commodity purchased components are grouped together in the above sensitivity 

analysis. Total Incremental Material Costs = $218.82 of which $160.37 are commodity purchased parts and 

$58.45 are raw material costs including in-process scrap. 

As discussed in Section 5.0, material costs include a combination of raw materials, 

material processing scrap, and commodity purchased parts. The value of commodity 

purchase parts, if excessive, can prove misleading relative to the contribution of each cost 

element within the cost model. In case studies which follow, greater efforts are being 

employed on binning unit costs, for those higher price commodities, into defined cost 

element categories. This is accomplished by using surrogate costing data for like 

components and developing standardized cost models (e.g., the Total Manufacturing Cost 

for a electromechanical device type “X” would have the predefined cost model - 35% 

material, 15% labor and 50% burden). Because surrogate costing data for the commodity 
14-2

purchase parts were not used in this case study, there will be a modest effect on the above 

sensitivity results (i.e., somewhat lower labor, burden, and somewhat higher material).
15-1 

15 GLOSSARY OF TERMS 

Assembly: generally refers to a group of interdependent components joined together to 

perform a defined function (e.g. turbocharger assembly, high pressure fuel pump 

assembly, high pressure fuel injector assembly). 

Buy: is the terminology used to identify those components or assemblies as ones in 

which a manufacturer would purchase versus manufacture. All parts designated as a 

“buy” part, within the analysis, only have a net component cost presented. Typically 

these types of parts are considered commodity purchase parts having industry established 

pricing. 

CBOM (Comparison Bill of Materials): is a system bill of materials, identifying all the 

subsystems, assemblies and components associated with the technology configurations 

under evaluation. The CBOM records all the high level details of the technology 

configurations under study, identifies those items which have cost implication as a result 

of the new versus base technology differences, documents the study assumptions, and is 

the primary document for capturing input from the cross functional team. 

Component: is the lowest level part within the cost analysis. An assembly is typically 

made up of several components acting together to perform a function (e.g. the turbine 

wheel in a turbocharger assembly). However, in some cases a component can act 

independently performing a function within a sub-subsystem or subsystem (e.g. exhaust 

manifold within the exhaust subsystem). 

Cost Estimating Models: are cost estimating tools, external to the Design Profit® 

software, used to calculate operation and process parameters for primary manufacturing 

processes (e.g. injection molding, die casting, metal stamping, forging). Key 

information calculated from the costing estimating tools (e.g. cycle times, raw material 

usage, equipment size) is inputted into the Lean Design® process maps supporting the 

cost analysis. The Excel base cost estimating models are developed and validated by 

Munro & Associates. 

Costing Databases: refer to the five (5) core databases which contain all the cost rates 

for the analysis. The material database lists out all the materials used throughout the 

analysis along with the estimated price/pound for each. The labor database captures 

various automotive, direct labor, manufacturing jobs (supplier and OEM), along with the 

associated mean hourly labor rates. The manufacturing overhead rate database contains 

the cost/hour for the various pieces of manufacturing equipment assumed in the analysis. 

A mark-up database assigns a percentage of mark-up for each of the four (4) main markup categories (i.e. end-item scrap, SG&A, profit, and ED&T), based on the industry, 

supplier size, and complexity classification. The fifth database, the packaging database, 

contains packaging options and costs for each case.
15-2

Lean Design® (a module within the Design Profit® software): is used to create 

detailed process flow charts/process maps. Lean Design® uses a series of standardized 

symbols, each base symbol representing a group of similar manufacturing procedures 

(e.g. fastening, material modifications, inspection). For each group, a Lean Design® 

library/database exists containing standardized operations along with the associated 

manufacturing information and specifications for each operation. The information and 

specifications are used to generate a net operation cycle time. Each operation on a 

process flow chart is represented by a base symbol, operation description, and operation 

time, all linked to a Lean Design® library/database. 

Make: is the terminology used to identify those components or assemblies as ones in 

which a manufacturer would produce internally versus purchase. All parts designated as 

a “make” part, within the analysis, are costed in full detail. 

MAQS (Manufacturing Assumption and Quote Summary) worksheet: is the 

standardized template used in the analysis to calculate the mass production 

manufacturing cost, including supplier mark-up, for each system, subsystem and 

assembly quoted in the analysis. Every component and assembly costed in the analysis 

will have a MAQS worksheet. The worksheet is based on a standard OEM (original 

equipment manufacturer) quote sheet modified for improved costing transparency and 

flexibility in sensitivity studies. The main feeder documents to the MAQS worksheets 

are process maps and the costing databases. 

MCRs (Material Cost Reductions): is a process employed to identify and capture 

potential design and/or manufacturing optimization ideas with the hardware under 

evaluation. These savings could potentially reduce or increase the differential costs 

between the new and base technology configurations, depending on whether an MCR 

idea is for the new or the base technology. 

Net Component/Assembly Cost Impact to OEM: is defined as the net manufacturing 

cost impact per unit, to the OEM, for a defined component, assembly, subsystem or 

system. For components produced by the supplier base, the net manufacturing cost 

impact to the OEM includes total manufacturing costs (material, labor, and 

manufacturing overhead), mark-up (end-item scrap costs, selling, general and 

administrative costs, profit, and engineering design and testing costs) and packaging 

costs. For OEM internally manufactured components, the net manufacturing cost impact 

to the OEM includes total manufacturing costs and packaging costs; mark-up costs are 

addressed through the application of an indirect cost multiplier. 

NTAs (New Technology Advances): is a process employed to identify and capture 

alternative advance technology ideas which could be substituted in for some of the 

existing hardware under evaluation. These advanced technologies, through improved 
15-3

function and performance, and/or cost reductions, could help increase the overall value of 

the technology configuration. 

Powertrain Package Proforma: is a summary worksheet comparing the key physical 

and performance attributes of the technology under study with those of the corresponding 

base configuration. 

Process Maps: are detailed process flow charts used to capture the operations and 

processes, and associated key manufacturing variables, involved in manufacturing 

products at any level (e.g. vehicle, system, subsystem, assembly, component). 

P-VCSM (Powertrain–Vehicle Class Summary Matrix): records the technologies 

being evaluated, the applicable vehicle classes for each technology, and key parameters 

for vehicles or vehicle systems that have been selected to represent the new technology 

and baseline configurations in each vehicle class to be costed. 

Quote: refers to the analytical process of establishing a cost for a component or 

assembly.

Sub-subsystem: refers to a group of interdependent assemblies and/or components, 

required to create a functioning sub-subsystem. For example, the air induction subsystem 

contains several sub-subsystems including the following: turbocharging, heat exchangers, 

and pipes, hoses and ducting.

Subsystem: refers to a group of interdependent sub-subsystems, assemblies and/or 

components, required to create a functioning subsystem. For example, the engine system 

contains several subsystems including the following: crank drive subsystem, cylinder 

block subsystem, cylinder head subsystem, fuel induction subsystem, and air induction 

subsystem. 

Subsystem CMAT (Cost Model Analysis Templates): is the document used to display 

and roll up all the sub-subsystem, assembly and component incremental costs associated 

with a subsystem (e.g. fuel induction, air induction, exhaust), as defined by the 

Comparison Bill of Material (CBOM). 

Surrogate part: refers to a part similar in fit, form and function as the part required for 

the cost analysis. Surrogate parts are sometimes used in the cost analysis when actual 

parts are unavailable. The cost of a surrogate part is considered equivalent to the cost of 

the actual part. 

System: refers to a group of interdependent subsystems, sub-subsystems, assemblies 

and/or components, working together to create a vehicle primary function (e.g. engine 

system, transmission system, brake system, fuel system, suspension system). 
15-4

System CMAT (Cost Model Analysis Template): is the document used to display and 

roll up all the subsystem incremental costs associated with a system (e.g. engine, 

transmission, steering), as defined by the CBOMs. 
 APPENDIX A.1 Powertrain-Vehicle Class Summary Matrix Excerpt – Case Study 

EPA Contract: EP-C-07-069 WA1-3 A-1, Page 1 of 1 
APPENDIX B.1 Powertrain Package Proforma - Case Study #0101 

EPA Contract: EP-C-07-069 WA1-3 B-1, Page 1 of 1 
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

X 02

Assumed the engine mounts are of reasonable quality for the Base Engine (NA PFI). As such, no changes would be required for Turbo DI

X 02

A Bracket - Engine Mount, Front X 02 01 - N0101 - 01 1 MT NR

X 10

A Bracket - Engine Lift X 02 10 - N0101 - 01 1 MT NR

X 75

A Bracket- Wire/Belt Guide (Front of Crank Damper ) X 02 75 - N0101 - 01 1 MT NR

X 80

A Bolt- Bracket, Engine Mount, Front X 02 80 - N0101 - 01 4 MT NRB Bolt - Bracket, Engine Mount, Front of Crank Damper X 02 80 - N0101 - 02 1 MT NR

C Bolt - Lift Eye X 02 80 - N0101 - 03 2 MT NR

03

 01

A. Shaft - Crank 03 01 - N0101 - 01 1 1 X X

Assumption: both shafts are made from Micro-AlloyedSteel such as C38N2 or C38Mod(+Vanadium). Due to reduced stroke and overall crankshaft length expect cost reduction.

Need to ensure additional features are equal between New and Base such as Rolled Fillets. Potential fo

from Nodu

X 02

A Flywheel Assembly - Engine X 03 02 - N0101 - 01 1 2

Single Mode Fly Wheel on Mini Cooper. Potentially twisting pulsations handled through Torque Converter tuning. Would not be able to tune out any degradation due to bending vibration. 

May not need to consider for smaller displacements,but will be mandatory with higher displacement Turbo DI Engines.

Dual Mass as cost Ris

03

A Rod Subassembly - Connecting 03 03 - N0101 - 01 4

A1 Bushing - Connecting Rod 03 03 - N0101 - 02 4 MP-3 X X Bushing required to accommodate higher loading at pin to connecting rod interface.

A2 Rod - Connecting 03 03 - N0101 - 03 4 MP-3 X X

Assumption: both have forged connecting rods made from either C70 or 36MnVS4 Micro Alloy Steel or equivalent. The connecting rods are approx. same length for both packages, however Turbo DI rods have thicker cross section to handle higher loads. 

To equalize the rod lenassumed cbetween 3-3.6. The Ccommon csame platf2.4L = 2.96Calculate cCooper L/R 

B Cap- Connecting Rod 03 03 - N0101 - 04 4 4 X X Assumption: both have forged connecting rods made from either C70 or 36MnVS4 Micro Alloy Steel.

 04

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

Engine Frames, Mountings & Brackets

Engine MountingsHanging-up EyeEngine BracketsBoltingsCrank ShaftFlywheels

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

Connect Rods (Assemblies:Connecting Rod, Connecting Rod Cap)Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins, Circlips)

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Crank Drives

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 1 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

A Piston - Engine, Machined 03 04 - N0101 - 01 4 5 X X X

Less mass, additional machining at piston crown and for piston pin clips. Top ring groove anodized for improved durability and reduction in the potential of micro welding the top compression ring in the groove. Assume same anti friction skirt coating on both New and Base Pistons. Post heat treat and machining premium on hypereutectic material.

B Ring/Clip - Piston Pin Retainer 03 04 - N0101 - 02 8 6 X Clips required for dual bearing slip fit design of pin to connecting rod & piston.

C Pin- Piston 03 04 - N0101 - 03 4 7 X X Assume same material, Chromium Steel SAE 5115 (16MnCr5). Quote mass difference only.D Compression Ring - Piston, Top 03 04 - N0101 - 04 4 8 X

Assume that the Turbo DI will use a more durable, low friction ring pack versus base. For Example, top compression ring, might be Silicon Manganese SpringSteel or Chrome Versus Cast or Nodular Iron. Coating may be Metallized Molybdenum versus a standard Manganese Phosphate.

Estimated to be Approx. $1.00 hit per ring pack (Top, Second and Oil Ring). Confirm with Tech. Specialist

E Compression Ring - Piston, 2nd 03 04 - N0101 - 05 4 9 X Similar to Top Compression Ring

F Oil Ring Subassembly

F1 Spacer/Expander/Coil Spring - Oil Ring, Piston 03 04 - N0101 - 07 4 10 X Assumption is higher end performing Oil Ring Assembly on Turbo DI versus NA PFI.

F2 Rail(s) - Oil Ring, Piston 03 04 - N0101 - 08 4 11 X Assumption is higher end performing Oil Ring Assembly on Turbo DI versus NA PFI.

X 80

A Bolt -Connector Rod Cap to Connecting Rod X 03 80 - N0101 - 01 8 12 NR

B Screw - Sensor Crankshaft to Block X 03 80 - N0101 - 02 1 13 NR

C Bolt -Flywheel to Crankshaft X 03 80 - N0101 - 03 6 14 NRD Dowel/Pin - Flywheel to Crankshaft X 03 80 - N0101 - 04 1 NR

X 85

X

90

A Bearing - Connecting Rod to Crank Shaft 03 90 - N0101 - 01 8 17 X

For Turbo DI, Rod Bearings would be upgraded from AlSn20Mn (Federal Mogul A-370) to a AlSn10Ni (Federal Mogul A-273)

X 99

A Sensor - Crankshaft X 03 99 - N0101 - 01 1 19 NR

B Encoder Wheel Assembly - Crankshaft Sensor X 03 99 - N0101 - 02 1 20 NR

Manufactuand NA PFassociation idea regard

C Cover - Sensor Crankshaft X 03 99 - N0101 - 03 1 MP-20 NR

X 04

01

Balancer shafts are not required on Turbo DI due tosmaller engine size. However they are incorporated in the Base NA PFI Engine. In this application, the balance shafts are integrated into the oil pump.

Oil pump integration isn't typical, may need access 

cost risk.

X 02

X

X 03

Static PartsDrivesMiscellaneous

Counter Balance Systems

Moved PartsBoltings: Connecting-Rod BoltsSealing ElementsBearing Elements: Connecting Rod Bearing Shells, Connecting Rod 

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 2 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

X

X 65

X

X 70

X

X 75

X

X 80

X

X 85

X

X 90

X

X 95

X

X 99

X

05

 01

A Cylinder Block Assembly - Machined w. Studs, Plugs, etc. 05 01 - N0101 - 01 1 1 X X X

Cost drivers between Turbo DI and NA PFI Engines1. Assume material for Turbo and Base Block are same and made from Diecast Hypereutectic Aluminum (B390)2. Turbo block smaller overall due to smaller bore size. Using CAE tools, a 11 mm reduction in bore size on the Base NA PFI (Base Bore 88, Turbo GDI Bore 77), would yield a weight savings of approx. 3.5kg. Will confirm with weight measurements on physical parts.3. Added diecast complexity and machining to incorporate features such as inter-bore cooling, Turbo cooling & oil supply and return lines, piston cooling jets, etc.

Industry trend in North America is moving away fromsand cast blocks to diecast block. Initially higher investment due to tooling complexity, but over timepays for itself.Need to verify material of block.

A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 05 01 - N0101 - 02 1 Reference Cylinder Block Assembly

A1.1 Cylinder Block Subassembly - Cast 05 01 - N0101 - 03 1 Reference Cylinder Block Assembly

A1.1.1 Cylinder Liners - Cast Iron 05 01 - N0101 - 04 1 X Both Engines have Cast cylinder liners. Calculate cost differential as a result of smaller liners for Turbo DI. Assume Nodular Cast Iron for both Engines, Spec?

02

Captured below in Bed Plate Assembly

 03

A Bed Plate Assembly - Machined w. Studs, Plugs, etc. 05 03 - N0101 - 01 1 2 X X

Both Engines Can operate using either a bedplate, crossbolted mains (rare on in-line engines), ladder caps, and two-bolted main bearing caps. The NVH characteristics degrade in the same order as above. For a clean sheet I4, bedplate construction would likely be the best option for both the NA PFI and Turbo DI engines. For cost analysis, will assume both engines have bed plate design and thus only compare size/weight difference. Material Diecast Hypereutectic Aluminum (B390)

Need to verify material spec of bedplate and caps.

A1 Bed Plate Assembly - Machined w/o. Studs, Plugs, etc. 05 03 - N0101 - 02 1 Reference Bed Plate Assembly

MiscCylinder Block

Cylinder Blocks

Connecting ElementsSealing ElementsBearing ElementsBracketsAdaptersPipes, Hoses, DuctingToolsCrankshaft Bearing CapsBedplates

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 3 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

A1.1 Bed Plate Subassembly - Cast 05 03 - N0101 - 02 1 Reference Bed Plate Assembly

A1.1.1 Bearing - Bolt Through - Insert, Steel 05 03 - N0101 - 03 5 X Assume same material only, size /weight difference only. Need material spec of inserted bearing caps.

 04

A Squirter - Oil, Piston Cooler 05 04 - N0101 - 01 4 3 X X Required for Turbo DI

B Bolt - Piston Cooler Valve/Retainer (Check Valve?) 05 04 - N0101 - 02 4 4 X X Required for Turbo DI

X 80

Boltings & Screws General

A Screw - Windage Tray to Bed Plate X 05 80 - N0101 - 01 4 5 NRB Bolt - Bed Plate to Block, Main (Crank Bearings Approx 3.5") X 05 80 - N0101 - 02 10 6 Assuming both engines would have Bed Plate design with same amount of main bear cap thru bolts. Check to see if size and grade are compatible between two engines.

C Bolt - Bed Plate to Block (Perimeter Approx. 1.5") X 05 80 - N0101 - 03 16 7

Assuming both engines would have Bed Plate design will make assumption same number of perimeter bolts required. Any difference would have negligible cost impact.

Reasoning larger perimeter on base versus Turbo DI,however greater loading on Turbo DI versus base, thus number of fasteners could potentially be equivalent. 

D Bolt - Bed Plate to Block ( Perimeter Approx 2.5") X 05 80 - N0101 - 04 2 8

Assuming both engines would have Bed Plate design will make assumption same number of perimeter bolts required. Any difference would have negligible cost impact.

Reasoning larger perimeter on base versus Turbo DI,however greater loading on Turbo DI versus base, thus number of fasteners could potentially be equivalent. 

E Screw - Sensor, Knock X 05 80 - N0101 - 05 1 9 NR

X

Dowel Pins/Plugs/Studs - Cylinder Block

A Plugs - Oil Galley X 05 80 - N0101 - 10 2 NRB Pin/Dowel - Locator Cylinder Block to Head X 05 80 - N0101 - 11 2 NR

C Pin/Dowel - Locator Cylinder Block to Bedplate X 05 80 - N0101 - 12 2 NRD Pin/Dowel - Block & Bed Plate (Flywheel Side), Accessory X 05 80 - N0101 - 13 2 NR

Dowel Pins/Plugs/Studs - Bed Plate

A Plug - Non Turbo Oil Indicator, Bedplate X 05 80 - N0101 - 20 1 Clean sheet design could eliminate.B Stud #1 - Accessory, Bed Plate (CC. Cat. Conv. Mnt) X 05 80 - N0101 - 21 2 NR

C Stud #2 - Accessory, Bed Plate X 05 80 - N0101 - 22 2 NR

X 85

A Seal - Crankshaft Front X 05 85 - N0101 - 01 1 10 NR

B Seal - Crankshaft Rear X 05 85 - N0101 - 02 1 11 NR

C Gasket/Seal - Block to Bed Plate (Deposit) X 05 85 - N0101 - 03 1 NR

90

A Bearing - Crankshaft, Block 1/2 Bearing (Top w. Lub. Pass.) 05 90 - N0101 - 01 5 13

For Turbo DI, main bearings would be upgraded from AlSn20Mn (Federal Mogul A-370) to a AlSn6Si4 (Federal Mogul A-590)

B Bearing/Shim - Crankshaft Thrust 05 90 - N0101 - 02 2 14 Material Upgrade - TBD Talk to Steve on possible material options.

C Bearing - Crankshaft, Block 1/2 Bearing (Bottom) 05 90 - N0101 - 03 5 13

For Turbo DI, main bearings would be upgraded from AlSn20Mn (Federal Mogul A-370) to a AlSn6Si4 (Federal Mogul A-590)

X 99

A Windage Tray - Bed Plate X 05 99 - N0101 - 01 1 15 NR

B Sensor - Knock X 05 99 - N0101 - 02 1 16 NR

C Cap - Bed Plate Rear Main Bolts X 05 99 - N0101 - 04 1 MP-16 NR

Bearing Elements: Crankshaft bearing shellsMiscellaneousBoltings/Dowel Pins/Plugs/Studs EtcSealing ElementsPiston Cooling

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 4 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

X

06

01

A Cylinder Head Assembly - Machined w. Studs, Valves, etc. 06 01 - N0101 - 01 1 1 X X X

Cost drivers between Turbo DI and NA PFI Engines1. Assume material for Turbo head A356 T6 versus Base A319 T7. A356 is required for high temperature strength and heat conductivity (better spark timing). 2. Turbo head smaller overall due to smaller bore size. Approx 46 mm shorter in length.3. Added diecast complexity and machining to incorporate features such as inter-bore cooling, side mount injectors, HP fuel rail and fuel pump mounting etc.

A1 Cylinder Head - Machined w/o. Studs, Valves, etc. 06 01 - N0101 - 02 1 Reference Cylinder Head AssemblyA1.1 Cylinder Head Subassembly - Cast 06 01 - N0101 - 03 1 Reference Cylinder Head Assembly

02

A Guide - Intake Valve X 06 02 - N0101 - 01 8 MT NR

B Guide - Exhaust Valve X 06 02 - N0101 - 02 8 MT NR

C Seat - Intake Valve 06 02 - N0101 - 03 8 MT Intake Seats would need to be upgraded - typical upgrade would be from Brico 310 to Como1207. D Seat - Exhaust Valve 06 02 - N0101 - 04 8 MT Exhaust seats would need to be upgraded - typical upgrade would be from MS25Cu to AR20. 

X 03

X

06

A Cap-Bearing Camshaft, Intake, Phaser Type X 06 06 - N0101 - 01 1 2 X X

Cost drivers between Turbo DI and NA PFI Engines1. Assume both Base and Turbo are made from same material, either Diecast Aluminum or Power Metal.2. Compare mass difference between both sets of caps.3. Machining considered equivalent, assumption bothengines have dVVT.

Negligible Weight Difference

B Cap-Bearing Camshaft, Intake Standard X 06 06 - N0101 - 02 9 3 X X

Cost drivers between Turbo DI and NA PFI Engines1. Assume both Base and Turbo are made from same material, either Diecast Aluminum or Power Metal.2. Compare mass difference between both sets of caps.

Negligible Weight Difference

C Cap, Head (Fuel Pump & Vacum Mount) 06 06 - N0101 - 03 1 4 X Cap unique to Turbo DI, required for HP fuel pump and Vacuum pump mounting and driving. Same as above

X 07

Cylinder Head

Cylinder Heads - Subsystem

Cam Shaft Speed SensorGuides for Valve TrainCamshaft Bearing Housing Valve Guides. Valve Seats

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 5 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

A Sensor - Cam Shaft, Speed X 06 07 - N0101 - 01 1 5 NR

20

A Cover Assembly- Cylinder Head Assembly X 06 20 - N0101 - 01 1 6

A1 PCV Subassembly (Built into cover) 06 20 - N0101 - 02 1

Crankcase vent system for DI engine is more difficult and requires better oil separation. The cost associated with upgraded PCV system is addressed in section 17 below.

A2 Cap - Oil Fill X 06 20 - N0101 - 03 1

A3 Insert - Fastener, Torque Loss X 06 20 - N0101 - 04 13A4 Insert - Threaded, Brass X 06 20 - N0101 - 05 3

80

Boltings & Screws General

A Bolt - Cap Bearing, Camshaft 06 80 - N0101 - 01 23 7 4 Extra Required for Extra CapB Bolt & Washer Assembly - Cylinder Head to Block M10X150 X 06 80 - N0101 - 02 10 8 NR: Same QTY, Size and Property Class used in both Engine Designs.

C Bolt & Washer Assembly - Cylinder Head to Block M8x96 X 06 80 - N0101 - 03 2 9 NR - Design choice based on integrating timing cover into block and head versus stand alone cover.D Bolt & Washer Assembly - Cylinder Head to Block M8x35 X 06 80 - N0101 - 04 1 10 NR - Design choice based on integrating timing cover into block and head versus stand alone cover.

E Bolt - Cam Sensor X 06 80 - N0101 - 05 1 11 NR

Dowel Pins/Plugs/Studs - Cylinder Head

A Bolt - Manifold, Exhaust 06 80 - N0101 - 10 10 Material upgrade on fasteners to stainless steal.B Bolt - Manifold, Intake X 06 80 - N0101 - 11 5 NR

C Pipe Plug - X 06 80 - N0101 - 12 1 NRD Core Plug - Press Fit (Φ18.5 Top) X 06 80 - N0101 - 13 1 NR

E Core Plug - Torx (Φ15) X 06 80 - N0101 - 14 1 NR

F Cup Plug - Press Fit (Φ40) X 06 80 - N0101 - 15 1 NR

G Core Plug - Press Fit (Φ36 Top) X 06 80 - N0101 - 16 1 NR

H Core Plug - Ball, Adjuster X 06 80 - N0101 - 17 1 NR

I Dowel - Cap, Bearing Camshaft X 06 80 - N0101 - 18 ?? NR

 85

A Gasket - Cylinder Head to Block 06 85 - N0101 - 01 1 12 X X Base Engine 2 layer MLS gasket for standard engine. Turbo DI would require 3 layer MLS gasket.

B Seal - Cover to Cylinder Head, Perimeter X 06 85 - N0101 - 02 1 13 NR

C Seal - Cover to Cylinder Head, Inner X 06 85 - N0101 - 03 1 14 NR

07

01

A Valve - Intake 07 01 - N0101 - 01 8 1 X X

Intake valves would need to be upgraded - typical upgrade would be from nitrided JIS SUH11 (Fe-1.5Si,8.5Cr, 0.5C) to Silichrome

Cylinder Head CoversBoltings: Cylinder Head, Cylinder Head Cover, ManifoldSealing Elements: Cylinder Head, Cylinder Head Cover, ....Inlet Valves

Valve Trains

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 6 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

 02

A Valve - Exhaust 07 02 - N0101 - 01 8 2 X X

Exhaust valves would need to be upgraded - typical upgrade would be from nitrided JIS SUH 35 (Fe, 9Mn,21Cr 4Ni, 0.5C and 0.4N) to Inconel head and Silichrome stem. Exhaust valves on Mini Cooper Turbo DI are Sodium filled as well. This design approach is notconsidered preferred and thus will note be included in cost analysis.

X 03

A Spring - Valve X 07 03 - N0101 - 01 16 3 NR

X 04

A Seat - Spring Upper X 07 04 - N0101 - 01 16 4 NR

B Retainer - Valve Spring X 07 04 - N0101 - 02 32 5 NR

C Seal-Seat Subassembly - Spring Lower (Seat, Seal and Coil Spring) X 07 04 - N0101 - 03 16 6 NR

X 05

A Adjuster - Hydraulic, X 07 05 - N0101 - 01 16 7 NR

B Follower- Roller Finger X 07 05 - N0101 - 02 16 8 NR

 06

A Camshaft Assembly - Intake Machined 07 06 - N0101 - 01 1 9 X X

1. Length of Camshaft reduced, mass reduction.2.Feature required to drive high pressure fuel pump for DI.3. Material Assumption, both Base and Turbo DI madefrom Nodular Cast Iron, Chilled

A1 Camshaft - Intake Machined 07 06 - N0101 - 02 1 Reference Camshaft Assembly-IntakeA2 Encoder Wheel - Intake X 07 06 - N0101 - 03 1 NR

B Camshaft Assembly - Exhaust Machined 07 06 - N0101 - 10 1 10 X X

1. Length of Camshaft reduced, mass reduction.2.Feature required to drive high pressure fuel pump for DI.3. Material Assumption, both Base and Turbo DI madefrom Nodular Cast Iron, Chilled

B1 Camshaft - Exhaust Machine 07 06 - N0101 - 11 1 Reference Camshaft Assembly-ExhaustB2 Encoder Wheel - Exhaust X 07 06 - N0101 - 12 1 NR

x 08

A Cam Phaser Assembly- Intake X 07 08 - N0101 - 01 1 11 Assumption Base and New Technology Packages have Dual VVT.

Outlet ValvesValve SpringsSpring Retainers, Cotters, Spring SeatsValve Actuation Elements: Rockers, Finger Followers, Hydraulic Lash Adjusters,...CamshaftsCamshaft Phaser and/or Cam Sprockets

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 7 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

B X 07 08 - N0101 - 20 1 12

NR - Assumption Base and New Technology Packages have Dual VVT. Thus exhaust sprocket is replaced with cam phaser assembly.

X 80

A Bolt - Cam Phaser, Camshaft, Intake X 07 80 - N0101 - 01 1 13 NR

B Bolt - Sprocket, Camshaft, Exhaust X 07 80 - N0101 - 02 1 14 NR

X 15X 16

E Bolt-Flange -Control Valve Oil To Cylinder Head X 07 80 - N0101 - 20 1 17 NR

X 99

A Control Valve - Oil, Intake VVT X 07 99 - N0101 - 01 1 18 NR

B X 07 99 - N0101 - 02 1 NR

X

X 08

01

A Sprocket - Crankshaft, Timing Drive 08 01 - N0101 - 01 1 1 X X Smart sprocket required to help counter act cyclic loading effects from Vacuum Pump and High Pressure Pump. Cost impact approx. $1-$2/Engine. Note, cost impact is associated with royalty fee; no manufacturing cost impact.

B Sprocket - Crankshaft, Oil Pump Drive X 08 01 - N0101 - 02 1 2 Surrogate Design

X 02

A Tensioner - Camshaft Timing X 08 02 - N0101 - 01 1 3 NR

X 03

A Tensioner Arm Assembly - Timing Chain, Lower X 08 03 - N0101 - 01 1 4 NR

A1 Tensioner Arm - RHSA2 Tensioner Arm - LHS

B Guide Assembly - Timing Chain, Upper Cam to Cam X 08 03 - N0101 - 10 1 5 NR

B1 Bracket - MountingB2 Guide Rail -Upper

X 05

A Chain Assembly - Timing X 08 05 - N0101 - 01 1 6 X X

May require heavier chain to handle additional timing drive load created by the vacuum pump and high pressure fuel pump.

Turbo DI has Roller Chain and NA PFI Engine has Inverted Tool/Silent Chain? Verify and determine if there is cost impact. Perhaps MCR on Base?

X 06

X

X 65

A Nose - Crankshaft, Timing Sprocket & Accessory Pulley X 08 65 - N0101 - 01 1 7 NR

X 80

Sprocket - Cam, Exhaust (Replaced with Exhaust Cam Phaser for Analysis)Control Valve - Oil, Exhaust VVT ( Added into assumption for cost analysis)BoltingsMiscellaneous

Timing Drives

Timing Wheels (Sprockets)TensionersGuidesBelts, ChainsCoversAdaptorsBoltings

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 8 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

A Bolt - Crankshaft Nose X 08 80 - N0101 - 01 1 8 NRB Washer - Crankshaft Nose X 08 80 - N0101 - 02 1 9 NR

C Bolt - Guide, Timing Chain Upper to cylinder head. X 08 80 - N0101 - 03 1 10 NRD Bolt - Tension Arm Subassembly to Block X 08 80 - N0101 - 04 3 11 NR

X

X 09

X 01

A Pulley/Damper Assembly - Crankshaft X 09 01 - N0101 - 01 1 1 X X NR - Turbo DI has single mode damper similar to Base NA PFI Engine

Dual mode dampers (DMD) reduce vibration in two directions. DMD's are typical for Turbo DI Engines.DMDs contain two separate dampers, one is for torsional crankshaft vibration (twisting) and the other is for bending vibration (bending up and down). 

B Wheel - Drive, Coolant Pump (Friction Driven) X 09 01 - N0101 - 02 1 2 NR

C Actuating Drive Assembly - Drive Pulley & Water Pump X 09 01 - N0101 - 03 1 3 NR

X 02

A Tensioner Assembly - Accessory Drive X 09 02 - N0101 - 01 1 4 NR

X 03

X

X 05

A Belt - Accessory Drive X 09 05 - N0101 - 01 1 5 NR

X 65

X

X 70

X

X 75

X

X 80

A Bolts - Pulley Crankshaft X 09 80 - N0101 - 01 3 6 NR

B Bolts - Drive Gear/Wheel Coolant Pump X 09 80 - N0101 - 02 3 7 NR

C Bolt - Tensioner Assembly (Secures to Alternator) X 09 80 - N0101 - 03 1 8 NRD Bolt - Actuating Drive Assembly - Drive Pulley & Water Pump X 09 80 - N0101 - 04 3 9 NR

Accessory Drives

PulleysTensionersGuidesBoltingBeltsAdaptorsPipes, Hoses, DuctingBrackets

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 9 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

10

01

A Manifold Assembly - Intake 10 01 - N0101 - 01 1 1 X X X

Assumptions: Intake manifold of Turbo DI is approximately half size of NA PFI Engine. Also base engine has intake tumbler to improve fuel atomization which helps meet cold start and idling targets. Although FEV feels additional tumbler device may be avoided with proper intake manifold design and head design.

Long runner intake manifolds are required in NA engines for tuning pressure wave. Want to make sure peak pressure hits at intake valve.

X 02

A Air Filter Box Assembly X 10 02 - N0101 - 01 1 2 NR

X 03

A Air Filter X 10 03 - N0101 - 01 1 3 NR

X 05

A Throttle Body Assembly - Electronically Controlled X 10 05 - N0101 - 01 1 4 NR

X 65

X

X 70

A Tube - Elbow, Air Intake to Filter Box X 10 70 - N0101 - 01 1 5 NR

B Tube - Flex, Air Intake to Elbow X 10 70 - N0101 - 02 1 6 NR

C Coupler - Tube Flex to Vehicle Mount X 10 70 - N0101 - 03 1 7 NRD Tube - Air Filter Box via MFS to Turbo Inlet X 10 70 - N0101 - 04 1 8 NR - This would go direct to ETB on Base Engine

X 75

A Bracket - Support, Intake Manifold X 10 75 - N0101 - 01 1 9 NR

X 80

A Nut - Intake Manifold Assembly to Cylinder Head X 10 80 - N0101 - 01 5 10 NR

B Nut- Bracket, Intake Manifold Support X 10 80 - N0101 - 02 2 11 NR

C Bolt- Bracket, Intake Manifold Support X 10 80 - N0101 - 03 1 12 NRD Bolt- Throttle Body to Intake Manifold X 10 80 - N0101 - 04 3 13 NR

E Bolt - Manifold Absolute Pressure X 10 80 - N0101 - 05 1 14 NR

F Grommet - Air Filter Box to Intake Manifold Mounting X 10 80 - N0101 - 06 3 15 NR

G Bolt - Air Filter Box To Intake Manifold X 10 80 - N0101 - 07 1 16 NR

H Duplicate Part to "F" X 17

I Insert - Air Filter - Intake Torque Loss Prevention X 10 80 - N0101 - 09 1 18 NR

J Clamp - Tube, Mass Air Flow Outlet X 10 80 - N0101 - 10 1 19 NR

K Clamp - Tube, Turbo Inlet X 10 80 - N0101 - 11 1 20 NR - This would clamp would be used to secure inlet tube directly to ETB

( Move to PCV) L Retainer - Turbo Intake Pipe to PCV Subassembly X 10 80 - N0101 - 12 1 21

X 85

A Gasket-Intake Manifold, Main Flange to Cylinder Head X 10 85 - N0101 - 01 1 22 NR

Intake ManifoldsAir Filter BoxAir FiltersThrottle Housing Assembly; including SuppliesAdapters: Flanges for Port Shut-offPipes, Hoses, DuctingBrackets

Intake Systems

Bolting & ClampsSealing Elements

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 10 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

B Gasket-Electronic Throttle Body to Intake Manifold X 10 85 - N0101 - 02 4 23 NR

C Gasket - Mass Flow Sensor (MFS) - Air Filter Box X 10 85 - N0101 - 03 1 24 NR

X 99

A Sensor - Mass Flow Meter, Hot Wire X 10 99 - N0101 - 01 1 25 NR

B Sensor - Manifold Absolute Pressure (MAP) X 10 99 - N0101 - 02 1 26 NR

11

01

A Fuel Rail w. High Pressure Sensor Assembly 11 01 - N0101 - 01 1

A1 Fuel Rail - High Pressure 11 01 - N0101 - 02 1 MP-1 X X X

As a result of higher fuel pressures (approx. 1200 psi), the following upgrades are required for DI versus PFI.1. Enhanced material grade.2. Thicker gauge material and structural enhancements.3. Additional attachment points.

A2 Sensor - Fuel, High Pressure 11 01 - N0101 - 03 1 MP-1 X 1 . Require pressure senor on fuel rail for DI; not required for PFI engine.

04

A Fuel Injector Assembly - Solenoid, 7 Hole 11 04 - N0101 - 01 4 2 X X X X 1. Replaces Low Pressure Port Injectors

 07

A Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off Intake Cam) 11 07 - N0101 - 01 1 3 X 1, Required for DI system, not required PFI system.

Look at cosback of intaRotary pumneed to cohead chankg) and adbore and fllobe on inta

 70

A Pipe Assembly - Fuel, High Pressure, Pump to Rail 11 70 - N0101 - 01 1 4 X 1. Connects High Pressure Pump to Fuel Rail on DI Engine; not required for PFI system.

B Tube & Hose Fuel LP & Purge Assembly X 11 70 - N0101 - 02 1 MP-4 NR

B1 Hose - Fuel Feed, Low Pressure X 11 70 - N0101 - 03 1 MP-4 NRB2 Hose - Fuel, Purge X 11 70 - N0101 - 04 1 MP-4 NR

B3 Retainer - Fuel Hoses to Bracket, LP & Purge X 11 70 - N0101 - 05 1 MP-4 NRB4 Retainer- Fuel Hose, LP & Purge X 11 70 - N0101 - 06 1 MP-4 NR

X

X 75

D Bracket Assembly - Tube, Fuel Low Pressure and Purge X 11 75 - N0101 - 01 1 MP-4 NR

 80

A Bolt - Fuel Rail 11 80 - N0101 - 01 4 5 X X DI has increased fastener quantity and size for securing fuel rail. 

B Bolt - Fuel Pump 11 80 - N0101 - 02 3 6 X Added for DI

C Retainer - Fuel Injector 11 80 - N0101 - 03 4 7 X Added for DID Washer, Retainer - Fuel Injector 11 80 - N0101 - 04 4 8 X Added for DI

E O-ring Retainer, Fuel Injector 11 80 - N0101 - 05 4 9 X Added for DI

F Spacer - Retainer, Fuel Injector 11 80 - N0101 - 06 4 10 X Added for DI

Fuel Induction Systems

Fuel Injection PumpsFuel InjectorsBracketsPipes, Hoses: Low Pressure, High PressureBoltingMiscellaneousFuel Rails

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 11 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

 85

A Seal - High Pressure Fuel Pump to Cylinder Head 11 85 - N0101 - 01 1 11 X Added for DI

12

01

A Manifold - Exhaust, Dual Wall 12 01 - N0101 - 01 1 1 X

Material upgrade required to a stainless steel capable of operating @ 1050C. Recommendation DIN 14826 Stainless Material.

Fabricated reduction oare packagof enginee

X 04

X

X 05

A Close Couple Catalytic Converter Subass'y- 3 Way (Exhaust Pipe Ass'Y) X 12 05 - N0101 - 01 1

NR - Estimate close coupled catalytic converter subsystem for Turbo DI technology and NA PFI engineapproximately equivalent in cost for this study based on similar power flows.

Consider higher temperatures and quicker light-off with direct injection offset by heat sink from turbo assembly hardware.

B Underbody Catalytic Converter Subass'y - ? Way (Under Body Ass'y) X 12 05 - N0101 - 02 1 NR

X 07

A Resonator Subassembly (Under Body Ass'y) X 12 07 - N0101 - 01 1 NR

B Muffler & Tail Pipe Subassembly (Under Body Ass'y) X 12 07 - N0101 - 02 1 NR

X 08

A Sensor Assembly - Oxygen/Lambda Before Catalyst X 12 08 - N0101 - 01 1 2 NR

B Sensor Assembly - Oxygen/Lambda After Catalyst X 12 08 - N0101 - 02 1 3 NR

X 65

A Flex Pipe Subass'y - Under Body Exhaust Ass'y to Exhaust Pipe Ass'y X 12 65 - N0101 - 01 1 4 NR

X 70

A Exhaust Pipe Assembly X 12 70 - N0101 - 01 1 5 NR

B Underbody Exhaust Pipe Assembly X 12 70 - N0101 - 02 1 6 NR

 75

A Bracket Subassembly - Exhaust Manifold w. Integrated Gasket 12 75 - N0101 - 01 1 7 X X 1. 3 layer sealing Turbo, 2 layer base NA PFI

B Bracket Subassembly- Heat Shield, Top, Turbo 12 75 - N0101 - 02 1 8 X Required to cover Turbo Assembly

C Bracket Subassembly - Heat Shield, Exhaust Outlet to Block X 12 75 - N0101 - 03 1 9 NR

X

D Bracket Subassembly - Exhaust Lower - CC. Cat. Conv. X 12 75 - N0101 - 05 1 MP-9 NR

X

Exhaust Systems

Oxygen SensorsAdaptersPipes, Hoses: Low Pressure, High PressureSealing ElementsExhaust ManifoldCollector PipesCatalystsSilencers (Mufflers)Brackets

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 12 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

E Strap - Manifold Mount Face (Torque Loss) X 12 75 - N0101 - 06 1 MP-10 NR - Components not industry standard for Base or Turbo DI

F Strap - Manifold Mount Face ( Torque Loss) X 12 75 - N0101 - 07 1 MP-10 NR - Components not industry standard for Base or Turbo DI

G Strap - Manifold Mount Face (Toque Loss) X 12 75 - N0101 - 08 1 MP-10 NR - Components not industry standard for Base or Turbo DI

H Bracket Subassembly #1 - C.C. Catalytic Con. To Bed Plate X 12 75 - N0101 - 09 1 MP-10 NR

I Bracket Subassembly #2 - C.C. Catalytic Con. To Bed Plate X 12 75 - N0101 - 10 1 MP-10 NR

J Bracket Subassembly - O2 Sensor (Before CC Cat. Conv.) X 12 75 - N0101 - 11 1 MP-10 NR

K Fixturing Hardware General - Exhaust Underbody Assembly X 12 75 - N0101 - NA NR

80

A Nut- Manifold Exhaust to Cylinder Head 12 80 - N0101 - 01 10 11 X X Material upgrade to stainless to handle higher exhaust temperaturesB Bolt - BRKT Heat Shield Turbo to Exhaust Manifold BRKT X 12 80 - N0101 - 02 12 12 NR - Similar fasteners exist for both designs

D Nut - BRKT Heat Shield Exhaust to Exhaust Manifold BRKT X 12 80 - N0101 - 04 1 14 NR - Similar fasteners exist for both designs

E Nut - C.C. Catalytic Converter to Bed Plate (Copper Nut) X 12 80 - N0101 - 05 2 MP-14 NR

F Nut - Turbo to C.C. Catalytic Converter 12 80 - N0101 - 06 3 MP-14 X Add for Turbo, Stainless Material?

G Nut - Exhaust Manifold to Turbo 12 80 - N0101 - 07 4 MP-14 X X

If there was no Turbo, assume same four nuts would be required to mount directly between manifold and exhaust pipe or Catalytic Converter Subassembly. However in Turbo DI case need to cover cost impact of Stainless Steel Nuts Versus Standard.

H Nut - Bracket, C.C. Catalytic Converter to Bed Plate X 12 80 - N0101 - 08 2 MP-14 NR

I Clamp Assembly - CC Catalytic Converter to Exhaust Pipe X 12 80 - N0101 - 09 1 MP-14 NR

J Fastening Hardware General - Exhaust Underbody Assembly X 12 80 - N0101 - TBD

X

 85

A Gasket - Turbo Inlet to Exhaust Manifold 12 85 - N0101 - 01 1 15 X Required with Turbo

B Gasket - Turbo Outlet to Catalytic Converter X 12 85 - N0101 - 02 1 MP-15

If there was no Turbo, assume gasket would be used to mount directly between manifold and exhaust pipe orCatalytic Converter Subassembly.

13

X 01

A Pan -Oil X 13 01 - N0101 - 01 1 1 NR

02

A Oil Pump Assembly 13 02 - N0101 - 01 1 2 X

Piston Cooling Jets, Turbo Charge lubrication and External Oil cooler will require increased oil capacity. Will need to access cost impact to moving to higher flowpump.

Typical oil pump pressure 50-60psi (10psi/1000rpm).

High volume pump typical has flow 20-25% higher. 

The physically larger surface area of the gears pushes more oil through the pump at the same rpm than a stock pump.

 06

Sealing Elements

BoltingOil Pans (Oil Sump)

Lubrication Systems, Oil Pans/Sumps

Oil FilterOil Pumps

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 13 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

A Filter Cooler Assembly - Oil (Includes Seals) 13 06 - N0101 - 01 1 3 X Require oil cooler in circuit to help cool oil going into Turbo assembly.

 70

A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 13 70 - N0101 - 01 1 4 X Required with Turbo

B Tube Assembly - Oil, Turbo to Engine Block (Piston Squirter's) 13 70 - N0101 - 02 1 5 X Required with Turbo

 80

A Screw - Oil Pan to Bed Plate X 13 80 - N0101 - 01 16 6 NR

B Bolt - Oil Pump Assembly X 13 80 - N0101 - 02 3 7 NR

C 13 80 - N0101 - 03 4 8 X Required with TurboD Bolt - Tube Assembly , Oil, Turbo Inlet 13 80 - N0101 - 09 1 9 X Required with Turbo

E Clamp - Tube Assembly, Oil, Cooler/Filter Outlet 13 80 - N0101 - 05 1 10 X Required with Turbo

F Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet 13 80 - N0101 - 06 2 11 X Required with Turbo

G Screw - Tube assembly Oil level Indicator X 13 80 - N0101 - 07 1 12 NR

 85

A Gasket - Oil Pan (Deposit) X 13 85 - N0101 - 01 1 NR

B Plug & Gasket Subassembly - Oil Pan, Drain X 13 85 - N0101 - 02 1 NR

C Seal - Tube Assembly, Oil, Turbo Inlet 13 85 - N0101 - 03 1 15 X Required for TurboD Compression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet 13 85 - N0101 - 04 4 16 X Required for Turbo

99

A Chain - Crank Shaft to Oil Pump X 13 99 - N0101 - 01 1 17 NR

X

B Tube Assembly - Oil Level Indicator X 13 99 - N0101 - 02 1 18 NR

C Sensor - Oil Pressure X 13 99 - N0101 - 03 1 19 NRD Cover - Oil Pump Chain X 13 99 - N0101 - 06 1 MP NR

E Sensor - Oil Temperature X 13 99 - N0101 - 04 1 20 NR

F Oil - Synthetic 13 99 - N0101 - 08 1 X X Synthetic oil required for turbocharged applications. Need to consider cost of initial factory fill.

14

01

A Pump Assembly - Coolant (Primary Mechanical) X 14 01 - N0101 - 01 1 1 NR

B Pump- Auxiliary Coolant, Electric 14 01 - N0101 - 02 1 2 X Required for Turbo Cooling following engine shut down.

X 02

A Thermostat/Coolant Flow Valve Assembly -Coolant X 14 02 - N0101 - 01 1 3

NR - Today having Integrated Electric Thermostat onTurbo DI and a conventional mechanical thermostat on the NA PFI is more typical. However I industry trend is moving towards electric thermostats for both technology levels. Thus assumption is same technology would exist in both applications.

Water PumpsBoltings & ClampsSealing Elements: Oil Pan Gasket,...

Bolt - Filter Cooler Assembly

Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure, Low Pressure.MiscellaneousThermostat Housing

Cooling Systems

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 14 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

Sensor - Thermostat (Integrated into Housing?) X 14 02 - N0101 - 02 1 Same as aboveSensor - Engine Temperature (Includes O-ring and Clip) X 14 02 - N0101 - 03 1 4 NR

 70

A Tube - Mech. Pump to Thermostat/Coolant Valve Ass'y X 14 70 - N0101 - 01 1 5 NR

B Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 14 70 - N0101 - 02 1 6 X Required for Turbo Cooling

C Hose Assembly - Auxiliary Pump to Turbo 14 70 - N0101 - 03 1 7 X Required for Turbo Cooling

D Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary Pump 14 70 - N0101 - 04 1 8 X Required for Turbo Cooling

E Hose - Radiator to Thermostat/Coolant Valve Assembly X 14 70 - N0101 - 05 1 NR

F Hose - Thermostat/Coolant Valve Assembly to Radiator X 14 70 - N0101 - 06 1 NR

G Hose - Heater Core to Thermostat/Coolant Valve Assembly X 14 70 - N0101 - 07 1 NR

H Hose - Thermostat/Coolant Valve Assembly to Heater Core X 14 70 - N0101 - 08 1 NR

 75

A Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y 14 75 - N0101 - 01 1 MP X Required to secure auxiliary electric pump for cooling turbo.

 80

A Bolt - Water Pump, Mechanical X 14 80 - N0101 - 01 5 13 NR

B Bolt - Thermostat/Coolant Flow Valve Assembly X 14 80 - N0101 - 02 3 14 NR

C Retainer(s) - Tube, Mech Pump to Thermostat Valve Ass'y X 14 80 - N0101 - 03 ?? 15 NRD Clamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ Thermo 14 80 - N0101 - 04 1 16 X Required for Turbo Cooling 

E Bolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKT Mount 14 80 - N0101 - 05 1 X Required for Turbo Cooling 

F Bolt-Hose, Inlet and Outlet @ Turbo 14 80 - N0101 - 06 2 18 X Required for Turbo Cooling 

G Bolt - Auxiliary Pump to Oil Filter Cooler Bracket Assembly 14 80 - N0101 - 07 2 19 X Required for Turbo Cooling 

I Clamp - Hose, Auxiliary Pump to Turbo 14 80 - N0101 - 09 1 21 X Required for Turbo Cooling 

J Clamp - Hose, Oil Filter Cooler Assembly to Auxiliary Pump 14 80 - N0101 - 10 2 22 X Required for Turbo Cooling 

K Clamp - Inlet and Outlet Radiator Hoses X 14 80 - N0101 - 11 4 NR

L Clamp - Inlet and Outlet Heater Core Hoses X 14 80 - N0101 - 12 4 NR

M Washer Banjo Bolt - Hose Coolant Inlet & Outlet Turbo 14 80 - N0101 - 13 4 MP-24 X Required for Turbo Cooling 

X 85

A Seal - Water Pump Mechanical X 14 85 - N0101 - 01 1 25 NR

B Seal - Thermostat/Coolant Flow Valve Assembly X 14 85 - N0101 - 02 1 26 NR

15

 01

A Turbo Charger Assembly 15 01 - N0101 - 01 1 1 X

Require for Turbo SystemTwin Scroll turbocharger capable of operating at 1050C EGT (Exhaust Gas Temperature) is currently the bestoption for transient operation.

Future cosmanifold sc

A1 Waste Gate Anti Surge Control Valve 15 01 - N0101 - 02 1 X Same as above

 05

Turbo Chargers (Assemblies)Heat Exchanger

Induction Air Charging Systems

Pipes, Hoses, DuctingBracketsBoltings & ClampsSealing Elements

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 15 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

A Cooler Assembly - Charged Air 15 05 - N0101 - 01 1 2 X Charged air cooler required for Turbo System

 65 70

A Tube Assembly - Turbo Waste Gate Pneumatic Control 15 70 - N0101 - 03 1 3 X Required for Turbo System

B Tube Ass'y w. Vehicle Tie Down Resonator, Air Cooler Inlet 15 70 - N0101 - 19 1

BI Tube - Turbo Outlet to Vehicle Mount Coupler 15 70 - N0101 - 20 1 4 X Part of air charge air cooling & delivery subsystem

B2 Coupler - Turbo Outlet Tube to Cooler Intake Tube 15 70 - N0101 - 21 1 5 X Part of air charge air cooling & delivery subsystemB3 Tube - Coupler to Charge Air Cooler 15 70 - N0101 - 22 1 6 X Part of air charge air cooling & delivery subsystem

C Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet X Part of air charge air cooling & delivery subsystem

C1 Tube - Charge Air Cooler Outlet 15 70 - N0101 - 01 1 7 X Part of air charge air cooling & delivery subsystemC2 Tube - Formed, Charge Air Cooler Tube Outlet 15 70 - N0101 - 31 1 8 X Part of air charge air cooling & delivery subsystem

D Tube - Elbow, Upper to Charged Air Coupler By-Pass 15 70 - N0101 - 40 1 9 X Part of air charge air cooling & delivery subsystem

E Tube - Coupler Y Branch to By-Pass 15 70 - N0101 - 41 1 10 X Part of air charge air cooling & delivery subsystem

F Tube - Elbow Coupler By-Pass to Throttle Body 15 70 - N0101 - 42 1 11 X Part of air charge air cooling & delivery subsystem

G Tube - Charged Air Bypass to Silencer 15 70 - N0101 - 43 1 12 X Part of air charge air cooling & delivery subsystem

H Tube - Flex Elbow, Silencer to Environment 15 70 - N0101 - 44 1 13 X Part of air charge air cooling & delivery subsystem

 75

A Bracket - Support, Turbo Assembly 15 75 - N0101 - 01 1 14 X Required to support mass of Turbo assembly hanging off Exhaust Manifold.

 80

A Bolt - Turbo Assembly to Exhaust Manifold (Moved-12) 15 80 - N0101 -

B Bolt - Turbo Assembly to Exhaust Pipe (Moved-12) 15 80 - N0101 - C Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 03 1 17 X Required to support Turbo Assembly

D Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 04 1 18 X Required to support Turbo Assembly

E Bolt - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 05 2 19 X Required for Turbo Assembly Subsystem

F Nut - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 06 1 20 X Required for Turbo Assembly Subsystem

H Clamp - Tube, Large, Turbo to Throttle Body 15 80 - N0101 - 08 9 22 X

Part of air charge air cooling & delivery subsystem. Note one clamp is accounted for in intake subsystem which would connect intake tube directly to ETB in base systems.

I Bolt - Tube, Charge Air Cooler to Vehicle 15 80 - N0101 - 09 2 X Part of air charge air cooling & delivery subsystem

J Screw - Sensor, Charge Air Temperature 15 80 - N0101 - 10 1 24 X Part of air charge air cooling & delivery subsystem

L Clamp - Tubing Charged Air By-Pass 15 80 - N0101 - 12 3 26 X Part of air charge air cooling & delivery subsystem

M Retainer - Vehicle, Charged Air By-Pass Elbow 15 80 - N0101 - 13 1 X Part of air charge air cooling & delivery subsystem

 99

A Vacuum Reservoir - Turbo Waste Gate 15 99 - N0101 - 01 1 29 X Required for Turbo Assembly Subsystem

B Value - Thrust Control, Turbo Waste Gate Pneumatic Control 15 99 - N0101 - 02 1 30 X Required for Turbo Assembly Subsystem

AdaptersPipes, Hoses, DuctingMiscellaneousBracketsBoltings, Clamps, Misc Fastening

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 16 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

C Sensor - Intake Temperature, Outlet Charged Air Cooler 15 99 - N0101 - 03 1 31 X Part of air charge air cooling & delivery subsystemD Baffle - Charge Air By-Pass 15 99 - N0101 - 04 1 32 X Part of air charge air cooling & delivery subsystem

17

02

A PCV ASSEMBLY - (Built into Cylinder Head Cover) X X

• The crankcase vent system for a DI engine is moredifficult and requires better oil separation. This may drive some additional cost into the system if a good result can not be engineered from a separator internal to the cam cover. 

A1 Valve - Non Return Intake Hose Side 17 02 - N0101 - 01 1 Evaluate upon teardown of PCV Subsystem

1

A2 Separator - Cyclone 17 02 - N0101 - 10 1 Evaluate upon teardown of PCV SubsystemA3 Valve - Pressure Control 17 02 - N0101 - 20 1 Evaluate upon teardown of PCV SubsystemA4 Valve - Oil Drain 17 02 - N0101 - 30 1 Evaluate upon teardown of PCV SubsystemA5 Valve - Non Return Intake Manifold Side 17 02 - N0101 - 40 1 Evaluate upon teardown of PCV Subsystem

X 70

A Hose Assembly- PCV H/W to Intake Manifold X 17 70 - N0101 - 01 1 6 NR

B Hose Assembly- Air Intake to PCV H/W (With Valve or Sensor??) X 17 70 - N0101 - 02 1 MP-6 NR

X 75

X

X 80

X

X 85

X

X 90

X

X 95

X

X 99

A Retainer - Hose Assembly - Air Intake to PCV H/W X 17 99 - N0101 - 01 1 6 NR

60

X 01

A Spark Plug X 60 01 - N0101 - 01 4 1 NR

 02

A Power Train Control Module (PCM) Assembly - Hardware 60 02 - N0101 - 01 X X

The PCM H/W is carry over except for the PFI drivers. GDI drivers use a 75-80VDC Boost Circuit and 25A Peak/Hold Drivers. The turbo is just another low-side driver really no cost. 

Estimated cost from Tech Team on GDI PCM may cost $40-45 more than a PFI PCM.

B Power Train Control Module (PCM) Assembly - Software 60 02 - N0101 - 50 X X

• Control system is much more complicated in order to control injection timing, split injections, fuel rail pressure, electric water pump, electric thermostat, etc.

Costs covered by Indirect Cost Multiplier

 03

Sealing ElementsBearing ElementsToolsMiscellaneous

Engine Management Systems, Engine Electronic Systems, Electrical Systems

Pipes, Hoses, DuctingBracketsBoltingsOil/Air SeparatorEngine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)Spark Plugs, Glow PlugsEngine Management Systems, Engine Electronic Systems

Breather Systems

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 17 of 18
APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101, 

2007 Mini Cooper 1.6L I4, Turbo, Direct Injection

Powertrain Description: 2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hp

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )

ITEM

ASY LVL QTY/ P.T.

Label # BRIEF EXPLANATION OF DIFFERENCES Notes: Addititional Items Requiring Investigation. Desig

C

<NR> = Item cost impact assumed 

unaffected or negligibly affected by technology differences

CHECK OFF ATTRIBUTES 

WHICH ARE DIFFERENT 

BETWEEN COMPARISON 

TECHNOLOGY PACKAGES

Part Existence

NAME/DECRIPTION PART NUMBER

SUBSYSTEM

SUB-SUBSYSTEM

Material/Finish(s) 

Weight/ Size

Function

Performance

QTY/P.T.

Royalty

ASSEMBLY

SUBASSEMBLY

COMPONENT

Default, indicates cost study required for identified item.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

GENERAL PART 

INFORMATION

X

?

X

A Ignition Coil Assembly - Single Spark 60 03 - N0101 - 01 4 2 X Require upgrade in ignition coils, Turbo typically 75-100 mJ, Base NAPFI 40-45mJ. Need to order ignition coil assemblyB Battery Assembly X 60 03 - N0101 - 20 1 NR

C Wire Harness Assembly #1 - Engine, Main 60 03 - N0101 - 30 1 3 X X X Added wiring complexity due to more sensors and actuators.

X 80

A Cover - COP harness X 60 80 - N0101 - 01 1 MP NR

70

X 01

A Starter Motor Assembly X 70 01 - N0101 - 01 1 1 NR

X 02

A Alternator Assembly X 70 02 - N0101 - 01 1 2 NR

X 03

A Power Steering Pump Assembly -Electronic X 70 03 - N0101 - 01 1 3 NR 

In future thof a standaShould inc

 04

A Vacuum Pump Assembly 70 04 - N0101 - 01 1 4 X On Turbo DI Vacuum pump required for brakes and accessories.

X 05

A Air Conditioning Compressor Assembly X 70 05 - N0101 - 01 1 5 NR

X 70

A Hose - Vacuum Pump, Brake Booster X 70 70 - N0101 - 01 1 6 NR

X 75

A Bracket - AC Compressor Mount X 70 75 - N0101 - 01 1 7 NR

B Bracket - Retention tube and wire harness X 70 75 - N0101 - 03 1 MP NR

 80

A Bolt - Vacuum Pump 70 80 - N0101 - 01 2 8 X Required to mount vacuum pump to head.

B Bolt - Starter Motor Assembly to Block X 70 80 - N0101 - 02 3 9 NR

D Bolt - Alternator Assembly to Block X 70 80 - N0101 - 03 3 10 NR

E Bolt - AC Comp. Mounting Bracket to Block & Bed Plate X 70 80 - N0101 - 04 4 11 NR

F Bolt - AC Compressor Assembly to Mounting Bracket X 70 80 - N0101 - 05 3 12 NR

G Fastener - Steering Pump Assembly to Vehicle X 70 80 - N0101 - 06 ?? 13 NR 

BoltingsPipes, Hoses, DuctingBracketsGeneratorsPower Steering PumpsVacuum PumpsAir Conditioning CompressorsBoltings

Accessories (Starter Engines, Generators, Power Steering Pumps, etc)

Starter Engines

File:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3

C.1, Page 18 of 18
APPENDIX D.1 Design Profit® Mapping Symbols 

EPA Contract: EP-C-07-069 WA1-3 D.1, Page 1 of 2 

Examples of symbols used in the Design Profit® Mapping Process: 

Part: Solid objects that are single entities. They have no other components 

attached or inside them, i.e. flange head bolt, one piece stamped bracket, single 

plastic injected molding. 

Sub Assembly: As the symbol implies, are parts inside or attached to other parts or 

products which have components inside them, i.e. bolts with captured washers, 

welded brackets, insert molded parts, purchased assemblies. 

Pre-processed Part: Are parts that have undergone additional processes before 

they can be used, i.e. Anodizing, powder coat, or paint. They typically contain a 

single part and one or more manufacturing processes. 

Multiple Touch Part: If a part or subassembly is handled more than once in the 

assembly of the product this stop sign symbol should be used in order to: 

• Ensure our part count is still correct. 

• Highlight the fact we are violating a good design principle 

Tool: Not all screwing operations can be done by hand like a jar lid; sometimes a 

tool will be needed. 
EPA Contract: EP-C-07-069 WA1-3 D.1, Page 2 of 2 

Fasten: Not all products and parts can be assembled right away. Some need an 

extra step like screwing. Get the part, put the part, and then fasten the part. 

Operation: Operations such as moving the product, operator movement, or 

changes to the direction of insertion, part manipulation, etc. In many cases, 

Operations are non value added (NVA) activities. 

Material Modification: Anytime the physical characteristics of a part are

changed, such as heat treating, and freezing, or, anytime material is removed, as in 

machining operations such as milling, boring, punching, drilling, etc. 

Inspect: Represents inspection steps in an assembly. Inspections are non-value 

added processes that should be eliminated or automated. 

In addition to the standard part symbols, parts are also further identified for 

fasteners and fluids: 

Fastener: Used to join two or more parts. 

Includes threaded and non-threaded fasteners, i.e. screws, washers, and glue. 

Fluid: Anything that is measured by volume rather than count. Includes oil, 

grease, coolant, and glue. 
APPENDIX E.1 Material Costing Database Excerpt 

Active Rate

2008

A. CARBON & ALLOY STEELS (SAE1000-9000 SERIES)A1. CARBON STEEL

A1.1 10XX Plain Carbon Steel Mn 1.00% Max

Low Carbon Steel SAE J403 1008/1010 Coil Brackets, Spacers LC-Steel-1000S, Coil 0.45 $ AMM Re

Medium Carbon Steel SAE J403 1018 Coil Splash Pans, Dampers, Windage Tray MC-Steel-1000S, Coil $ Online M

0.55 

Industria

Low Carbon, Hot Dip Galvanized Steed.

SAE J403 1008/1010 Coil PCV Baffles LC-GSteel-1000S, Coil $ Premium 

0.48

Medium Carbon Steel SAE J403 1018 Bar MC-Steel-1018, Bar $ Metals E

0.74 

High Carbon Steel SAE J403 1040 Bar (1-3") HC-Steel-1040S, Bar 0.80 $ Online M

A1.3 12XX Resulfurized and Rephosphorized

12L14 Leaded Bar Bar Bushings, Inserts, Couplings LC-Steel-1214, Bar 0.62 $ Online M

1215 Replacement to 12L14 Bar Bushings, Inserts, Couplings LC-Steel-1215, Bar 0.62 $ PurchasLow Carbon Steel Tubing 1215 Tube Metal Tubing coolant lines, oil lines, etc. LC-Steel-1215, Tubing 0.62 $ Estimate

A6. CHROMIUM-MOLYBDENUM (CHROMOLY) STEELS

A6.1 41XX

41xx Bar Injector Body A-Steel-41XXS, Bar 0.78 $ Assigne

Chrome-Moly-Vanadium Steel 32CrMoV13 Bar Bearings, Crank shafts MA-Steel-CrMoV, Bar 0.98 $ Compos

4140RH 42CrMoS4 Bar Crankshafts, axle journals, gears, pushrods. A-Steel-4140, Bar 0.78 $ Compos

4130 Spring Steel Heat-Treatable C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil Direct Injector Spring Clips HC-Steel-4130, Coil $ Surroga

1.18 

4130 C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil, 0.04" to 0.125" HC-Steel-4130, Coil 

0.04"-0.125"

$ Online M

1.18 

4130 Tight Thickness Tolerance. C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil, 0.05" to 0.08", Tight Thickness Tolerance

HC-Steel-4130, Coil 0.04"-0.08"

$ Kmac 2.79

A7. NICKLE-CHROMIUM-MOLYBDENUM STEELS

A7.1 43XX Ni 1.82%, Cr 0.50-0.80%, Mo 0.25%

300M SAE 4340Mod Vacuum melted high 

strength, super alloy.

Drive shafts, Con. Rods MA-Steel-300M, Bar 0.89 $ Compos

Ni-Chrome-Moly SAE 4330/4340 Bar 1-7" Planetary Gear Carrier, Shafts MA-Steel-43XXM, Bar 1.08 $ Online M

A7.4 86XX Ni 0.55%, Cr 0.50 Mo 0.20% 

8620, Case Hardening Steel SAE 8620, 21NiCrMoS5 Bar Driving Bevel Gears, Crown Wheels, Gears, 

Shafts, Bolts for automotive and gear components.

A-Steel-8620, Bar 0.70 $ Compos

A9. CHROMIUM STEELS

A9.4 51XX Cr 0.80% or 0.87% or 0.92% or 1.00% or 

1.05%.

SAE 5115 C0.15, Si0.25, Mn0.50, Cr0.60, Bar A-Steel-51XX, Bar 1.00 $ Surroga

SAE 5140/5145 Bar Gears, Shafts A-Steel-5140, Bar 1.00 $ Kmac, R

A9.5 51XXX Cr 1.02%, C 1.00% Min.

Chromium Steel, High Carbon, Bearing Grade, Unpolished Mill Finished, Annealed

SAE 52100 Bar >0.5" Bearing Races A-Steel-52100 Bar 1.00 $ Kmac, R

A10. CHROMIUM-VANADIUM STEELS

A10.1 61XX Cr 0.60% or 0.80% or 0.95%, V 0.10% or 

0.15%

SAE 6150 Bar 1-8" Park pawl, park gear $ Kmac 0.67

 Carbon Ranges: Low 0.05-0.15%, Mid. 0.16-0.29%, High 0.30-1.10%, Ultra High 1-2%Cr 0.50% 0r 0.80% or 0.95%, Mo 0.12% or 0.20% or 0.25% or 0.30%

Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class 

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.Y.

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3 E.1, Page 1of 7 
APPENDIX E.1 Material Costing Database Excerpt 

Active Rate

2008 Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class 

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.Y.

B. HIGH STRENGTH LOW ALLOY (HSLA) and MICRO ALLOY STEELSB2. Micro Alloy Steels

A2.1 Mn 1.75%

C70S6 C0.72%, Si0.22%, Mn0.49%, S0.062%, V0.04% Typical Air Cooled Forging Steel Forged fractured split rods MA-Steel-C70S6, Bar 0.70 $ Compos

36MnVS4 Bar

Crankshafts, Cracked Forged Rods, Short and Long-shaft Ball Points, threaded heavy duty anchor bolts.

MA-Steel-MnVS, Bar 0.73 $ Compos

C. STAINLESS STEELS (SAE100-600Series)C1. 300 Series - Austenitic Chromium-Nickel Alloys

C1.1 304 General Purpose

304 Bar Valves and Tubing S-Steel-304, Bar 1.65 $ MEPS, s

304/304L Coil Exhaust Systems, Fuel tanks S-Steel-304, Coil 1.6 $ MEPS, s

4 

304/304L Sheet or Cast Housings for Catalytic Converters and 

Turbochargers.

S-Steel-304, Cast 1.39 $ MEPS, s

304 Tube Fuel Rail S-Steel-304, Tube 1.65 $ Estimate

C1.1.1 316 Mo added to increase corrosion resistance.

316 Bar Valves and Tubing S-Steel-316, Bar 2.44 $ MEPS, s

316/316L C reduced for weldability Coil S-Steel-316, Coil 2.72 $ MEPS, s

316/316L C reduced for weldability Cast/Sheet Housings for Catalytic Converters and 

Turbochargers.

S-Steel-316, Cast 2.82 $ MEPS, s

C1.1.2 309/309S CR & Ni increased for high temperature.

310/310S Same as 309, only more so. Internal Components for Turbochargers (e.g.. 

Rotors)

S-Steel-310, Cast 4.23 $ Place H

C1.1.5 303 S added to improve machining.

303Se Se (Selenium) added for better machined 

surfaces.

303 Bar Valves and Tubing S-Steel-303, Bar 1.55 $ MEPS, s

303L Bar Valves and Tubing S-Steel-303L, Bar 1.65 $ MEPS, s

C1.1.6 301 Cr and Ni lowered to increase work hardening.

C1.1.7 MISC.

21-2N/21/4N (EV8) Austenitic Precipitation Hardening Chrome 

Manganese Nickel Steel: Cr:23/20%, Ni4.50/3.25%, Mn: 10/8% etc.

Bar Intake & Exhaust Valves S-Steel-21_14N, Bar 7.56 $ Point Pr

C2. 400 Series Ferritic Chromium Alloys

C.2.1.1 442 Cr Increased to improve scaling resistance,

422 Bar Intake & Exhaust Valves S-Steel-422, Bar 7.56 $ Point Pr

Harden by cold working, can not be hardened by heat treating, Non Magnetic in annealed condition. Excellent corrosion 

resistance and usually good formability.Can not be hardened through heat treatment and only moderately hardened by cold working. The are magnetic, have 

good ductility and resistance to corrosion and oxidation. 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3 E.1, Page 2of 7 
APPENDIX E.1 Material Costing Database Excerpt 

Active Rate

2008 Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class 

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.Y.

C3. 400 Series Martensitic Chromium Alloys

C3.1.5 440C C increased for highest hardness. Cr 

increased for corrosion resistance.

Bar Intake & Exhaust Valves S-Steel-440C, Bar 4.56 $ Point Pr

440B C decreases slightly to improve toughness.440A Same as 440B, only more so.

D. CAST IRONSD1. Nodular/Ductile Cast Iron

Nodular / Ductile Iron (80-55-06) ASTM A536-80-55-06 $0.90-$1.2/lb finished 

casting

Crankshaft, blocks Nodular Iron, Cast 0.35 $ AISI, ME

Nodular / Ductile Iron (100-70-03) ASTM A536-100-70-03 $0.90-$1.2/lb finished 

casting

High Strength Cam shafts i.e.., driving HP fuel pumps.

Nodular Iron, Gr100/70/03, Cast

$ Estimate 

0.42 

Ni-resist cast iron, D5S D5S, ASTM A-439-84 Housing - Turbo Exhaust NiResist Iron, D5S, Cast 3.50 $ Estimate 

Silicon Molybdenum Cast Iron 4% Si & 1% Mo Housing-Block Center, Turbo Support SiMo Ductile Iron, Cast 0.60 $ Estimate 

D2. Malleable Cast Irons

Malleable Cast Iron $0.90-$1.2/lb finished 

casting

Crankshaft, camshafts, blocks Malleable Cast Iron 0.4 $ AISI, ME

1

D3. Grey Cast Iron

Grey Cast Iron SAE J431 Grade 3000 (3.1-3.4C, 1.9-2.3Si, 

Mn 0.60-0.90)

Engine Blocks Grey Iron, Cast 0.35 $ Estimate 

E. ALUMINUM ALLOYS E1. Wrought Alloys

E1.1 2XXX Al-Cu Alloys

2024 2024-T3/T4/T351 Bar Ø0.5-2.5" Aluminum-2024, Bar 2.38 $ Aircraft 

Metals, 

2024 2024-T3/T4/T351 Sheet, 0.032"-0.125" Aluminum-2024, Sheet 3.41 $ Online M

E1.2 3XXX Al-Mn Alloys

3003, 3005, 3012 Aluminum Magnesium Braze-clad welded radiator tubes, heater cores, radiator, heater 

and evaporative fins, heater inlet and outlet tubes, oil coolers, and air conditioner liquid lines, radiator heater and evaporative parts, extruded condenser tubes.

Aluminum-3000S, Coil 0.84 $ Aluminu

3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.032-0.125" 

(0.75-3.15mm)

Heat Exchangers Aluminum-3003, Coil A 1.41 $ Aluminu

3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.003-0.009" 

(0.075-0.22mm)

Heat Exchangers Aluminum-3003, Coil B 1.93 $ Lynch E

E1.3 4XXX Al-Si Alloys

4032 4032-T651 Bar Ø1.0-2.5" Aluminum-4032, Bar 1.44 $ Kmac

E1.4 5XXX Al-Mg Alloys

5052H32 5052 H32 Coil 0.025-0.125" Aluminum-5052, Coil 1.52 $ Online M

E1.5 6XXX Al-Mg-Si Alloys

6062 6062-T6511 Bar Ø0.5-1.5" Spool valves Aluminum-6062, Bar 1.45 $ Online M

6061 6061-T6511 Bar Ø0.5-3.0" Aluminum-6061, Bar 1.50 $ Metals E

Metal Co

E1.8 Misc

3003-H14 Clad 4XXX Aluminum-Manganese Cladded Tube Seamless welded tube - 

thickness 0.012-0.02" (0.3-0.5mm)

Heat Exchangers Cladded Aluminum3003, Tube $ Lynch E

2.28

Typical Cast Irons are 95%wt. Iron, 2.1-4%wt Carbon, and 1-3%wt. Silicon.(Temper Designations F>as Fabricated, O>annealed, H> Strain-hardened, W>Solution heat-treated. T> Thermally 

treated, usually solution heat-treated, quenched and precipitation hardened.

Are hardenable through heat treatment. They are magnetic. The resistance corrosion in mild environments. They have 

fairly good ductility, and some can be heat treated to Tensile Strengths exceeding 200kpsi. 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3 E.1, Page 3of 7 
APPENDIX E.1 Material Costing Database Excerpt 

Active Rate

2008 Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class 

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.Y.

E2. Casting Alloys ( Hypoeutectic 8.5-10.5, Eutectic 11-12, 16-18 Hypereutectic Material )

2XX Al-Cu Alloys3XX Al-Si + Cu and/or Mg Alloys

319 T5 Al-3.5Cu-6Si Hypoeutectic/Perm. Manifolds, cylinder heads, blocks, internal engine 

parts

Aluminum-A319-T5, Cast $ CRU gro

1.15

332 / F132 8.5-10Si, 2.0-4.0Cu, Ni0.10 Hypereutectic, common 

grade, large recycled composition (Die.)

Hypoeutectic Aluminum-332, Cast 1.24 $ CRU gro

356 T6 or A356 7Si-0.3 Mg alloy Hypoeutectic (Perm.) Engine blocks, flywheel, oil pan, pump bodies, cyl 

heads, manifolds, transmission cases

Aluminum-356-T6, Cast 1.20 $ CRU gro

A380.1 Al-9Si-3Cu(Fe) Hypoeutectic (Die.) Blocks, transmission housings/parts, fuel 

metering devices, oil pump cyl heads, 

Aluminum-A380, Cast 1.10 $ CRU gro

B380 Al-9Si-3Cu(Fe) Hypoeutectic (Die) Blocks, transmission housings/parts, fuel 

metering devices, oil pump cyl heads, 

Aluminum-B380, Cast 1.18 $ CRU gro

384 Eutectic (Die) Pistons, automatic transmissions Aluminum-384, Cast 1.14 $ CRU gro

B390.0 Hypereutectic aluminum-silicon Hypereutectic (Die.) High-wear applications such as ring gears and 

internal transmission parts, Hypereutectic pistons,cylinder blocks

Aluminum-B390, Cast 1.20 $ CRU gro

A383 AlSi10Cu2 Hypoeutectic (Die.) Blocks 3HA Piston Alloy AlSi12Cu4Ni2Mg

F. POWDER METALS (Classification per MPIF Standard 35)F1. PM Structural Materials: Ferrous and Non-ferrous Crank timing sprockets or gears, cam shaft timing 

sprocket or gears, Transmission clutch hubs, ATM planetary ring gear, Cam lobe on composite cam shaft, impellers.

Ferrous MaterialsF1.1 Iron and Carbons Steel

Sintered Powdered Metal (Iron base powder alloy)

SAE 1541 PM-SMF-Iron Base 1.00 $ 

F1.10 Stainless Steel - 300 Series Alloy

304/304L PM-SMF-SS304 4.92 $ 3x Cost 

316 Stainless SS-316N2, 17Cr,12Ni,2.5Mo ρ=6.5g/cm^3,UTS=60ksi Good Corrosion Resistance, Appearance PM-SMF-SS316 8.16 $ 3x Cost 

F1.11 Stainless Steel - 400 Series Alloy

430 Stainless SS-430N2, 17Cr ρ=7.1g/cm^3,UTS=60ksi Good Corrosion Resistance, Appearance

410 Stainless SS-41, 13Cr, 0.8Si, 0.8Mn

ρ=6.1g/cm^3,UTS=66.7ksi DI Solenoids PM-SMF-SS410 4.50 $ Need Pr

F1.12 MiscellaneousNon-Ferrous MaterialsF1.21 Aluminum and Aluminum Alloys

PM Aluminum - Structural Components 4.4Cu/0.5Mg/0.6Si

Ys/UTS in ksi: w. T4 HT, 31/38 w. T6 HT 47.5/48.1

Cam Caps PM-SMNF-Aluminum $ 3.50 

F2. P/F Steel Part Materials

F2.0 Carbon Steel

Powdered forged HS150/160 Connecting Rods PF-SMF-HS150/160 0.70 $ Compos

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3 E.1, Page 4of 7 
APPENDIX E.1 Material Costing Database Excerpt 

Active Rate

2008 Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class 

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.Y.

G. MAGNESIUM WROUGHT & CASTING ALLOYSG2. Cast AlloysG2.1 AZ91

AZ91 AZ91D Mg Al9 Zn1 Valve Covers Magnesium-AZ91D, Cast $ 2.42 USGS, A

Centrac

H. TITANIUM WROUGHT & CASTING ALLOYSH1. Wrought Alloys

Titanium (Sponge Only) Titanium-Sponge, Cast 4.71 $ USGS

Titanium (6AL V4) Bar High Pressure Bellows Pump Titanium-6AL4V, Bar 34. $ Longbow 37

Titanium (6AL V4) Plate Titanium-6AL4V, Plate 43.91 $ Longbow

H2. Cast Alloys

Titanium (6AL V4) Ingot Titanium-6AL4V, Cast 21.30 $ Longbow

J. COPPER WROUGHT & CASTING ALLOYS (BRONZE & BRASS)

J6.3 High Lead Tin Bronze & Lead Free Bronze (LC-M/H, T=H, C/E=G RS=G, H/W=H)

C93200 SAE 660 Bearing Bronze bushings, pump fixtures, pump impellers, fuel 

pump bushings, thrust washers, insert bearings, gears, valves and valve components, etc.

Bronze-932, Bar 2.56 $ InfoMine 

C89320 Lead Free Replacement to C93200 89%Cu, 6%Sn, and 

5%Bi

Turbocharger Spindle Bushings (Floating Type) Bronze-89320, Bar 2.56 $ Estimate 

Oilite Bronze Bearing Alloy SAE841 1" Round Bar $ Wisco A

5.31

J6.4 Aluminum Bronze(LC-VH, T=VH, C/E=P RS=M, H/W=VH)

ASTM C63000, C63020 Nickel Aluminum Bronze Valve stems and trim, bearings and bushings, 

fasteners, gears

Ni-Al-Bronze-630000, Bar

$ InfoMine 

2.44 

J6.12 Silicon Brasses (LC=? , T=? , C/E=? , RS=?, H/W=?)

C87500 (500) Silicon Brass, 82-4Si-14Zn Bearings, gears, impellers, rocker arms, valve 

stems, brush holders, bearing races, small boat propellers.

Si-Brass-87500, Bar 2.11 $ InfoMine 

CDA 673 - Silicon Manganese Brass

C67300 Bar Si-Brass-67300, Bar 3.71 $ Atlas Br

J6.13 Brass General 

C36000 CDA 360 Fluid connectors, threaded inserts for plastic 

parts, sensor bodies, thermostat parts

Brass-36000, Bar 1.70 $ InfoMine 

J6.14 Cooper General 

Copper >99.0% Pure Wire harnesses Copper-Pure, Wire 2.45 $ InfoMine

K. NICKEL WROUGHT & CASTING ALLOYSK1. Wrought Alloys

K1.1 Inconel®

Inconel® 751/HEV3 Bar Exhaust Valves Inconel-751, Bar 12.22 $ Point pr

Inconel® 713 Coil Coil Heat Shields, Turbo Inconel-713C, Coil 6.00 $ Estimate 

Nickel Alloy - Internal Turbo Parts General Coil Heat Shields, Turbo Nickel Alloy Gen, Cast 5.00 $ Need M

Inconel® 713 Coil Cast Inconel-713, Cast 6.00 $ Estimate 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3 E.1, Page 5of 7 
APPENDIX E.1 Material Costing Database Excerpt 

Active Rate

2008 Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class 

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.Y.

L. COBALT WROUGHT & CASTING ALLOYSL1. Wrought Alloys

L1.1 Stellite®

Stellite® 6 Base Co, Cr 27-32%, W4-6%, C0.9-1.4%, 

Others Ni, Fe, Si, Mn, Mo

Bar Exhaust Valves Stellite 21.00 $ 

Q. THERMOPLASTIC POLYMNERS

Q1. Polyamide (PA/Nylon)

Nylon 6 PA6 Nylon6, Inject. 1.65 $ IDES, P

Nylon 6 (15 % glass) PA6 GF15 Air cooler tube outlet Nylon6-15GF, Inject. 1.59 $ IDES, PNylon 6 (30 to 35% glass) PA6 GF30 Vacuum reservoir, Intake manifold Nylon6-30GF, Inject. 1.76 $ IDES, P

Nylon 66 PA66 Fuel injector connector, hose asm end - pump to 

turbo, chain tension guides

Nylon66, Inject. 1.74 $ IDES, P

Nylon 66 (30 to 35% glass) PA66 GF30 Intake manifold, cylinder cover, cooler asm end 

caps

Nylon66-30GF, Inject. 1.54 $ IDES, P

Nylon 66 (50% glass) PA66 GF50 cooler asm end caps Nylon66-50GF, Inject. 1.54 $ IDES, P

Nylon 66, 40% Fibrous Mineral Reinforced

PA66 FMR40% GMNA Spec PA66 060 Direct Injection Connectors Nylon66-40FMR, Inject. 1.54 $ Estimate 

Nylon 12 PA12 Reservior tube Nylon12, Inject. 3.03 $ IDES, P

Nylon 12, 30% glass PA12, GF30 PCV Hose Intake End $ IDES, P

3.41 

Q3. Polyethylene

HDPE Copolymer - blowmolding HDPE Rubberized blow molded air induction ducts and couplings. HDPE BM Grade 0.72 $ 

Q4. Polybutylene Terephthalate (PBT)

Polybutylene Terephthalate PBT GF20 Silencer Air by-pass PBT-GF20, Inject. 1.46 $ IDES, P

Q5. Acrylonitrile Butadiene Styrene (ABS)

ABS Beta patch for battery closeout $ Plastic N

0.72

Q6. Polypropylene (PP)

Random copolymer blow molding grade.

PP High strength blow molded air induction ducts. HD Polypro 0.87 $ 

Q9. Polyvinylchloride (PVC)

Blended NBR-PVC Rubberized blow molded air induction ducts and 

couplings.

NBR-PVC 1.27 $ 

Q9. Miscellaneous

Teflon® Polytetrafluoroethylene PTFE, Inject. 6.70 $ IDES, P

R. THERMOSET POLYMERS

R1 Hydrocarbon, Unsaturated.

Natural rubber / TSR20 NR Hoses, O-rings, gaskets, tubes Thermoset-NR 2.14 $ CMAI, R

Synthetic poly-isoprene rubber IR Hoses, O-rings, gaskets, tubes Thermoset-IRStyrene butadiene rubber SBR Hoses, O-rings, gaskets, tubes Thermoset-SBR 1.32 $ CMAI, R

Butadiene rubber BR Hoses, O-rings, gaskets, tubes Thermoset-BR 0.65 $ CMAI

Polubutadiene rubber PBR Hoses, O-rings, gaskets, tubes Thermoset-PBR 0.82 $ The Inno

Polubutadiene rubber - glass filled PBR GF20 Auxiliary water pump housing Thermoset-PBR-GF20 1.17 $ The Inno

Butyl rubber IIR Hoses, O-rings, gaskets, tubes Thermoset-IIR 1.37 $ The Inno

Chloro- and bromo- butyl rubber CIIR, BIIR Hoses, O-rings, gaskets, tubes

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3 E.1, Page 6of 7 
APPENDIX E.1 Material Costing Database Excerpt 

Active Rate

2008 Cat. Item Material Description Industry Specification

Supplemental 

Specification 

Information

Application Examples Material Class 

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.Y.

R2. Hydrocarbon Saturated

Ethylene propylene (diene) rubber EPM/EPDM Hoses, O-rings, gaskets, tubes Thermoset-EPDM 1.83 $ The Inno

R3. Nitrile

Nitrile butadiene rubber NBR Hoses, O-rings, gaskets, tubes Thermoset-NBR 1.27 $ The Inno

R8. Fluorocarbon

Fluoro elastomer FKM ERG valve seals Thermoset-FKM 12.50 $ Plastics 

R10. Polyimide

Polyimide - Vespel SP-21 PI 30%Carbon filled thrust washers, bearings and seals — low-friction 

properties, work with or without lubrication.

Thermoset-Vespel SP21CF30

$ PT onlin

35.18 

Polyimide - Vespel SP-21 PI 30%Glass filled Thermoset-Vespel 

SP21GF30

$ PT onlin

24.36 

R12. Polyurethane

Polyurethane elastomer, esterbased AU Hoses, O-rings, gaskets, tubes Thermoset-AU 1.77 $ Rubber 

R13. Silicone

Silicone rubber MVQ Hoses, O-rings, gaskets, tubes Thermoset-MVQ $ 4.50

R14. Miscellaneous

SBR Tubing w. Fiber Reinforcement

SBR Reinforced Tubing SBR-Fiber Rein., 

Extruded

$ 1.40 x $

1.85

SBR Tubing w. Metal Reinforcement

SBR Reinforced Tubing SBR-Metal Rein., 

Extruded

$ 1.70 x $

2.24

SBR Tubing w. Fiber Reinforcement and outer wrap.

SBR Reinforced Tubing SBR-Fiber Rein. W. 

Outer Wrap, Extruded

$ 1.55 x $

2.05

S. THERMOPLASTIC ELASTOMERS

Olefinic Syn Rubber M-group Synthetic Hoses, O-rings, gaskets, tubes TPE-PP/EPDM, Inject. 0.99 $ Plastics 

Olefinic TPE+TD33 Cooling Fan Shroud $ Plastics 

1.04

U. AUTOMOTIVE FLUIDS

Engine Oil - Synthetic (Price/Quart) Engine Oil-Synthetic 1.40 $ Need Pr

Engine Oil - Regular (Price/Quart) Engine Oil-Regular 0.60 $ Need Pr

V. PLATINGS & COATINGS

V.1 Aluminum Cladding

Aluminum-Silicon Cladding 3003 Sheet w. 4047 Cladding 

Single Cladding, Combined Material Thickness <0.060" 

Thickness tolerance 10% Base Material Thickness

Oil Coolers, Radiators, etc Aluminum-3003/4047A, 

Cladding

$ Sue rec

1.65 

Aluminum-Silicon Cladding 3003 Sheet w. 4047 Cladding 

Single Cladding, Combined Material Thickness >0.060" 

Thickness tolerance 10% Base Material Thickness

Oil Coolers, Radiators, etc Aluminum-3003/4047B, 

Cladding

$ Sue rec

2.10 

Brake and Oil Line Platings GALFAN Hot Dipped Thickness 4mil or 0.1 

mm

GALFAN 0.56 $ http://me

Notes1. Material composition analysis was used when published data on specific materials was not available. Materials in related categories with similar compositions and established price points were compared to the material under in

compared and deltas defined to determine cost differences. Since the cost differences are calculated from the elemental deltas, it was necessary to obtain the cost of the base elements. The costs of base elements such as zinc, 

published in several websites. Next, the cost per pound for each element that varied was multiplied by the delta percentage difference. These incremental elemental cost differences (plus/minus) were added to the base price poininvestigation. Lastly the surcharge was added to the cost to obtain the final alloy price per pound. A surcharge is a special charge to cover unexpected or temporary costs in the production of alloys. Surcharges are also posted on 

customers of pending price fluctuations. 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3 E.1, Page 7of 7 
APPENDIX E.2 Labor Costing Database Excerpt 

Production Year Start (Baseline) 2008

Active 

Rate

2008

Mean 

Hourly 

Wage

Indirect 

Labor 

Rate 

Ratio

ILRR

"%"

Indirect 

Labor 

Contribution

$/Hour

MRO 

Labor 

Rate 

Ratio

MLRR

"%"

MRO Labor 

Contribution

$/Hour

Fringe 

Allocation 

"%"

Fringe 

Contribution

$/Hour

I. Motor Vehicle Parts Manufacturing - NAICS 336300 Default or Average Rate $16.42 49.42% $8.18 16.16% $2.67 52.00% $14.18 

1 51-2022 Electrical and Electronic 

Equipment Assemblers

Assemble or modify electrical or electronic equipment, such as computers, test equipment telemetering systems, electric motors, and batteries.

Sensors, Controllers, PCM

Electrical Assembly $29.69 $12.85 40% $5.14 12% $1.54 52% $10.16 

2 51-2023 Electromechanical 

Equipment Assemblers

Assemble or modify electromechanical equipment or devices, such as servomechanisms, gyros, dynamometers, magnetic drums, tape drives, brakes, control linkage, actuators, and appliances.

Electro Mechanical Assemblies, Motors, Actuators, etc.

Electromechanical Assembly $37.35 $16.06 40% $6.42 13% $2.09 52% $12.78 

3 51-2031 Engine and Other Machine 

Assemblers

Construct, assemble, or rebuild machines, such as engines, turbines, and similar equipment used in such industries as construction, extraction, textiles, and paper manufacturing.

Complex Assembly Complex Assembly $42.90 $17.64 43% $7.59 17% $3.00 52% $14.68 

4 51-2092 Team Assemblers Work as part of a team having responsibility for 

assembling an entire product or component of a product. Team assemblers can perform all tasks conducted by the team in the assembly process and rotate through all or most of them rather than being assigned 

General Assembly General Assembly $35.51 $13.66 52% $7.10 19% $2.60 52% $12.15 

5 51-2093 Timing Device Assemblers, 

Adjusters and Calibrators

Perform precision assembling or adjusting, within narrow tolerances, of timing devices, such as watches, clocks, or chronometers. Exclude "Watch Repairers" (49-9064).

Assembly operations 

requiring feedback during assembly

Precision Assembly $25.74 $11.07 40% $4.43 13% $1.44 52% $8.81 

6 51-2099 Assemblers and Fabricators, 

All Other

All assemblers and fabricators not listed separately. Stand alone complete 

assembly stations.

Work Cell Assembly $49.78 $19.38 50% $9.69 19% $3.68 52% $17.03 

7 51-4011 Computer-Controlled 

Machine Tool Operators (Metal & Plastic)

Operate computer-controlled machines or robots to perform one or more machine functions on metal or plastic work pieces.

CNC Stations, CNC Operator $35.70 $15.25 42% $6.41 12% $1.83 52% $12.21 

8 51-4021 Extruding and Drawing 

Machine setters, Operators, and Tenders, Metal & Plastic

Set up, operate, or tend machines to extrude or draw

thermoplastic or metal materials into tubes, rods, hoses, wire, bars, or structural shapes.

Extrusion, Seals, 

Gaskets, Grommets, etc. (Considered to be mostly polymer materials with exception of some very ductile metals)

Extruding/Drawing Operator $54.35 $18.92 67% $12.68 22% $4.16 52% $18.59 

9 51-4022 Forging Machine Setters, 

Operators, and Tenders, Metal and Plastic

Set up, operate, or tend forging machines to taper, shape, or form metal or plastic parts.

Cold or Hot Forgings ( Majority Metals).

Forging Operator $38.52 $14.65 54% $7.91 19% $2.78 52% $13.18 

10 51-4031 Cutting, Punching, and 

Press Machine Setters, Operators and Tenders, Metal and Plastic

Set up, operate, or tend machines to saw, cut, shear,slit, punch, crimp, notch, bend, or straighten metal or plastic material.

Stamping & Forming, Metal or Plastic

Cut/Punch/Forming Operator $42.18 $16.04 54% $8.66 19% $3.05 52% $14.43 

11 51-4032 Drilling and Boring Machine 

Tool Setters, Operators, and Tenders, Metal and Plastic

Set up, operate, or tend drilling machines to drill, bore, ream, mill, or countersink metal or plastic work pieces.

Smaller Machining Stations and/or with less automation

Drilling/Boring Operator $43.35 $18.52 40% $7.41 14% $2.59 52% $14.83 

12 51-4033 Grinding, Lapping, Polishing 

, and Buffing Machine Tool Setters, Operators, and Tenders, Metal and Plastics

Set up, operate, or tend grinding and related tools that 

remove excess material or burrs from surfaces, sharpen edges or corners, or buff, hone, or polish metal or plastic work pieces.

Smaller Grinding/Honing Stations and/or with less automation

Grinding/Polishing Operator $44.48 $17.63 50% $8.82 16% $2.82 52% $15.22 

13 51-4034 Lathe and Turning Machine 

Tool Setters, Operators, and Tenders, Metal and Plastic

Set up, operate, or tend lathe and turning machines to 

turn, bore, thread, form, or face metal or plastic materials, such as wire, rod, or bar stock.

Smaller Turning Station and/or with less automation

Lathe/Turning Operator $37.60 $16.49 38% $6.27 12% $1.98 52% $12.86 

14 51-4035 Milling and Planing Machine 

Setters, Operators, and Tenders, Metal and Plastic.

Set up, operate, or tend milling or planing machines to mill, plane, shape, groove, or profile metal or plastic work pieces.

Milling Operations Milling/Planing Operator $35.37 $15.41 40% $6.16 11% $1.70 52% $12.10 

Item SOCS Code (BLS) Direct Labor Title (BLS) Direct Labor Description (BLS) Typical Application Association Labor Classification

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.2, Page 1 of 4 
APPENDIX E.2 Labor Costing Database Excerpt 

Production Year Start (Baseline) 2008

Active 

Rate

2008

Mean 

Hourly 

Wage

Indirect 

Labor 

Rate 

Ratio

ILRR

"%"

Indirect 

Labor 

Contribution

$/Hour

MRO 

Labor 

Rate 

Ratio

MLRR

"%"

MRO Labor 

Contribution

$/Hour

Fringe 

Allocation 

"%"

Fringe 

Contribution

$/Hour

Item SOCS Code (BLS) Direct Labor Title (BLS) Direct Labor Description (BLS) Typical Application Association Labor Classification

15 51-4072 Molding, Core making, and 

Casting Machine Setters, Operators, and Tenders, Metal & Plastic

Set up, operate, or tend metal or plastic molding, casting, or core making machines to mold or cast metal or thermoplastic parts or products.

Molding and Casting Operators

Mold/Cast/Sinter Operator $43.52 $15.15 66% $10.00 23% $3.48 52% $14.89 

16 51-4081 Multiple Machine Tool 

Setters, Operators, and Tenders, Metal and Plastic.

Set up, operate, or tend to more than one type of cutting or forming machine tool or robot.

Will not use, too general and overlap with other categories.

$44.85 $17.46 52% $9.08 17% $2.97 52% $15.34 

17 51-4122 Welding, Soldering, and 

Brazing Machine Setters, Operators, and Tenders.

Set up, operate, or tend welding, soldering, or brazing machines or robots that weld, braze, solder, or heat treat metal products, components, or assemblies. 

Include workers who operate laser cutters or laser-beam machines.

Various Welding Operations

Welding/Soldering Operator $44.96 $18.72 42% $7.86 16% $3.00 52% $15.38 

18 51-4191 Heat Treat Equipment 

Setters, Operators, and Tenders, Metal and Plastic

Set up, operate, or tend heating equipment, such as heat-treating furnaces, flame-hardening machines, induction machines, soaking pits, or vacuum equipment to temper, harden, anneal, or heat-treat metal or plastic objects.

Heat Treat Heat Treat Operator $46.52 $16.28 69% $11.23 19% $3.09 52% $15.92 

19 51-4193 Plating and Coating Machine 

Setters, Operators, and Tenders, Metal and Plastic

Set up, operate, or tend plating or coating machines to 

coat metal or plastic products with chromium, zinc, copper, cadmium, nickel, or other metal to protect or decorate surfaces. Include electrolytic processes.

Plating & Finishes Plating/Coating Operator $55.17 $20.86 60% $12.52 14% $2.92 52% $18.87 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.2, Page 2 of 4 
APPENDIX E.2 Labor Costing Database Excerpt 

Production Year Start (Baseline) 2008

Active 

Rate

2008

Mean 

Hourly 

Wage

Indirect 

Labor 

Rate 

Ratio

ILRR

"%"

Indirect 

Labor 

Contribution

$/Hour

MRO 

Labor 

Rate 

Ratio

MLRR

"%"

MRO Labor 

Contribution

$/Hour

Fringe 

Allocation 

"%"

Fringe 

Contribution

$/Hour

Item SOCS Code (BLS) Direct Labor Title (BLS) Direct Labor Description (BLS) Typical Application Association Labor Classification

II. Motor Vehicle Manufacturing - NAICS 336100 Default or Average Rate $21.54 48.00% $10.21 14.56% $3.08 160.00% $55.73 

1 51-2022 Electrical and Electronic 

Equipment Assemblers

Assemble or modify electrical or electronic equipment, such as computers, test equipment telemetering systems, electric motors, and batteries.

Electronic Subassembly Build-Up/Assembly

Electrical Assembly-OEM $71.82 $18.54 38% $7.05 11% $2.04 160% $44.20 

2 51-2031 Engine and Other Machine 

Assemblers

Construct, assemble, or rebuild machines, such as engines, turbines, and similar equipment used in such industries as construction, extraction, textiles, and paper manufacturing.

Complex Assembly: Engines, Transmissions

Complex Assembly-OEM $97.34 $26.18 34% $8.90 9% $2.36 160% $59.90 

3 51-2092 Team Assemblers Work as part of a team having responsibility for 

assembling an entire product or component of a product. Team assemblers can perform all tasks conducted by the team in the assembly process and rotate through all or most of them rather than being assigned 

General Assembly General Assembly-OEM $83.31 $20.28 44% $8.92 14% $2.84 160% $51.27 

4 51-2099 Assemblers and Fabricators, 

All Other

All assemblers and fabricators not listed separately. Stand alone complete 

assembly stations.

Work Cell Operator-OEM $95.87 $24.42 38% $9.28 13% $3.17 160% $59.00 

5 51-4011 Computer-Controlled 

Machine Tool Operators (Metal & Plastic)

Operate computer-controlled machines or robots to perform one or more machine functions on metal or plastic work pieces.

CNC Stations, CNC Operator-OEM $68.07 $17.00 42% $7.14 12% $2.04 160% $41.89 

6 51-4022 Forging Machine Setters, 

Operators, and Tenders, Metal and Plastic

Set up, operate, or tend forging machines to taper, shape, or form metal or plastic parts.

Cold or Hot Forgings, Metal or Plastic

Forging Operator-OEM $58.96 $12.74 58% $7.39 20% $2.55 160% $36.28 

7 51-4031 Cutting, Punching, and 

Press Machine Setters, Operators and Tenders, Metal and Plastic

Set up, operate, or tend machines to saw, cut, shear,

slit, punch, crimp, notch, bend, or straighten metal or plastic material.

Stamping & Forming, Metal or Plastic

Cut/Punch/Forming OperatorOEM $96.00 $20.86 58% $12.10 19% $3.96 160% $59.08 

8 51-4032 Drilling and Boring Machine 

Tool Setters, Operators, and Tenders, Metal and Plastic

Set up, operate, or tend drilling machines to drill, bore, ream, mill, or countersink metal or plastic work pieces.

Smaller Machining Stations and/or with less automation

Drilling/Boring Operator-OEM $112.19 $28.02 40% $11.21 14% $3.92 160% $69.04 

9 51-4033 Grinding, Lapping, Polishing 

, and Buffing Machine Tool Setters, Operators, and Tenders, Metal and Plastics

Set up, operate, or tend grinding and related tools that 

remove excess material or burrs from surfaces, sharpen edges or corners, or buff, hone, or polish metal or plastic work pieces.

Smaller Grinding/Honing Stations and/or with less automation

Grinding/Polishing Operator-OEM $98.71 $22.87 50% $11.44 16% $3.66 160% $60.74 

10 51-4034 Lather and Turning Machine 

Tool Setters, Operators, and Tenders, Metal and Plastic

Set up, operate, or tend lathe and turning machines to 

turn, bore, thread, form, or face metal or plastic materials, such as wire, rod, or bar stock.

Smaller Turning Station and/or with less automation

Lathe/Turning Operator-OEM $83.05 $21.73 37% $8.04 10% $2.17 160% $51.11 

11 51-4035 Milling and Planing Machine 

Setters, Operators, and Tenders, Metal and Plastic.

Set up, operate, or tend milling or planing machines to mill, plane, shape, groove, or profile metal or plastic work pieces.

Milling Operations Milling/Planing Operator-OEM $71.22 $18.02 41% $7.39 11% $1.98 160% $43.82 

12 51-4072 Molding, Core making, and 

Casting Machine Setters, Operators, and Tenders, Metal & Plastic

Set up, operate, or tend metal or plastic molding, casting, or core making machines to mold or cast metal or thermoplastic parts or products.

Molding and Casting Operators

Mold/Cast/Sinter Operator-OEM $77.92 $15.69 68% $10.67 23% $3.61 160% $47.95 

13 51-4081 Multiple Machine Tool 

Setters, Operators, and Tenders, Metal and Plastic.

Set up, operate, or tend more than one type of cutting or forming machine tool or robot.

Smaller Machines and/or with High Automation for Injection Molding or Casting

Will not use, too general and overlap with other categories.

$87.55 $19.47 56% $10.90 17% $3.31 160% $53.88 

14 51-4122 Welding, Soldering, and 

Brazing Machine Setters, Operators, and Tenders.

Set up, operate, or tend welding, soldering, or brazing machines or robots that weld, braze, solder, or heat treat metal products, components, or assemblies. 

Include workers who operate laser cutters or laser-beam machines.

Various Welding Operations

Welding/Soldering Operator-OEM $103.78 $27.34 35% $9.57 11% $3.01 160% $63.87 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.2, Page 3 of 4 
APPENDIX E.2 Labor Costing Database Excerpt 

Production Year Start (Baseline) 2008

Active 

Rate

2008

Mean 

Hourly 

Wage

Indirect 

Labor 

Rate 

Ratio

ILRR

"%"

Indirect 

Labor 

Contribution

$/Hour

MRO 

Labor 

Rate 

Ratio

MLRR

"%"

MRO Labor 

Contribution

$/Hour

Fringe 

Allocation 

"%"

Fringe 

Contribution

$/Hour

Item SOCS Code (BLS) Direct Labor Title (BLS) Direct Labor Description (BLS) Typical Application Association Labor Classification

15 51-4191 Heat Treat Equipment 

Setters, Operators, and Tenders, Metal and Plastic

Set up, operate, or tend heating equipment, such as heat-treating furnaces, flame-hardening machines, induction machines, soaking pits, or vacuum equipment to temper, harden, anneal, or heat-treat metal or plastic objects.

Heat Treat Heat Treat Operator-OEM $137.35 $28.10 69% $19.39 19% $5.34 160% $84.52 

16 51-9122 Painters, Transportation 

Equipment

Operate or tend painting machines to paint surfaces of 

transportation equipment, such as automobiles, buses, trucks, trains, boats, and airplanes. Include painters in 

auto body repair facilities.

Painting Painter Operator-OEM $105.77 $23.38 60% $14.03 14% $3.27 160% $65.09 

III. Miscellaneous

1

NA Not Applicable Category to be referenced when there is no impact on 

Labor associated with technology change.

Not Applicable $0.00 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.2, Page 4 of 4 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

Activ

2

A. THERMOPLASTIC PROCESSING

A1. Injection Molding ( General, Station Based, Potential for Material Considerations)

1 Injection Molding Machines (1500-3000 Ton) 1 Chiller Inject. Mold, LS $12 2 Dryer 3 3 Mold Temperature Control Unit 4 4 Basic Material Handling Equipment5 5

1B 1 Injection Molding Machines (800-1500 Ton) 1 Chiller Intake Manifolds, Inject. Mold, MLS $9

2 2 Dryer3 3 Temperature Control Unit4 4 Basic Material Handling Equipment5 5

1B 1 Injection Molding Machines (400-800 Ton) 1 Chiller Inject. Mold, LS $5

2 2 Dryer3 3 Mold Temperature Control Unit4 4 Basic Material Handling Equipment5 5

1B 1 Injection Molding Machines (200-400 Ton) 1 Chiller Timing Chain Tensioner, Guides, Inject. Mold, SMS $2

2 2 Dryer3 3 Mold Temperature Control Unit4 4 Basic Material Handling Equipment5 5

1B 1 Injection Molding Machines (55-150 Ton) 1 Chiller Inject. Mold, SS $1

2 2 Dryer3 3 Mold Temperature Control Unit4 4 Basic Material Handling Equipment5 5

C. CASTING PROCESS

C1. Diecasting - Aluminum (General, Station Based )

1 Cold Chamber Die Casting Machine (2600-3800 Ton) 1 Melting Equipment Engine Blocks, Bed Plates, etc Diecast, LS, HC, w. Inserts $3

2 2 Automation for applying mold release agents, removing 

cast parts, etc.

3 3 Die Cast Mold Temperature Control Unit 

4 4 Robotic equipment for loading inserts into the tool.

5 51 Cold Chamber Die Casting Machine (2600-3800 Ton) 1 Melting Equipment Diecast, LS $3

2 2 Automation for applying mold release agents, removing 

cast parts, etc.

Diecast, LS, HC $3

3 3 Die Cast Mold Temperature Control Unit4 45 51 Cold Chamber Die Casting Machine (1800-2600 Ton) 1 Melting Equipment Diecast, MLS $2

2 2 Automation for applying mold release agents, removing 

cast parts, etc.

Diecast, MHC $2

3 3 Die Cast Mold Temperature Control Unit4 45 5

1B 1 Cold Chamber Die Casting Machine (1000-1800 Ton) 1 Melting Equipment Diecast, MS $1

2 2 Automation for applying mold release agents, removing 

cast parts, etc.

$1

3 3 Die Cast Mold Temperature Control Unit4 45 51 Cold Chamber Die Casting Machine (500-1000 Ton) 1 Melting Equipment Diecast, SMS $1

2 2 Automation for applying mold release agents, removing 

cast parts, etc.

Diecast, LMC $1

3 3 Die Cast Mold Temperature Control Unit45 7

A1.5 Injection Molding, Small Size and/or 

Low Complexity

A1.1 Injection Molding, Large Size and/or 

High ComplexityInjection Molding, Medium-Large Size and/or Moderate-High ComplexityAluminum Diecasting, Small-Medium Size and/or Low-Moderate Complexity

Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

Aluminum Diecasting, Medium Size and/or Moderate Complexity.Injection Molding, Medium Size and/or Moderate ComplexityInjection Molding, Small-Medium Size and/or Low-Moderate ComplexityAluminum Diecasting, Medium-Large Size and/or Moderate-High Complexity.

Cat. Item Burden Title

A1.2A1.4A1.3

C1.3C1.5C1.1 Aluminum Diecasting, Large, 

Complex Components with Inserts

C1.2 Aluminum Diecasting, Large Size 

and/or High Complexity.

C1.4

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 1 of 9 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

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Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

1B 1 Cold Chamber Die Casting Machine (0-500 Ton) 1 Melting Equipment Diecast, SS $7

2 2 Automation for applying mold release agents, removing 

cast parts, etc.

3 3 Die Cast Mold Temperature Control Unit4 45 7

E. Stamping & Forming Processes

E1. Stamping & Forming, General, Station Based

1 Vertical Stamping Press, Tonnage 2000-3000 1 Uncoiler & Straightener Stamp/Form, 2XLS $2

2 2 3 3 4 45 5

1B 1 Vertical Stamping Press, Tonnage 1500-2000 1 Uncoiler & Straightener Stamp/Form, XLS $1

2 23 34 45 5

1B 1 Vertical Stamping Press, Tonnage 1000-1500 1 Uncoiler & Straightener Stamp/Form, LS $1

2 2 Stamp/Form, MLS, MHC $13 34 45 5

1B 1 Vertical Stamping Press, Tonnage 800-1000 1 Uncoiler & Straightener Stamp/Form, MLS $1

2 2 Stamp/Form, SMS, MHC $3 34 45 5

1B 1 Vertical Stamping Press, Tonnage 600-800 1 Uncoiler & Straightener Stamp/Form, MS $8

2 23 34 45 5

1B 1 Vertical Stamping Press, Tonnage 400-600 1 Uncoiler & Straightener Stamp/Form, SMS $6

2 2 Stamp/Form, SMS, LMC $63 34 45 5

1B 1 Vertical Stamping Press, Tonnage 200-400 1 Uncoiler & Straightener Stamp/Form, SS $4

2 23 34 45 5

1B 1 Vertical Stamping Press, Tonnage 60-200 1 Uncoiler & Straightener Stamp/Form, XSS $2

2 23 34 45 5

1B 1 Vertical Stamping Press, Tonnage 0-60 1 Uncoiler & Straightener Stamp/Form, Terminals $1

2 23 34 45 5

E1.7E1.8E1.9E1.2

Stamping & Forming, Small Size Stamping & Forming, Extra Large Size,

E1.1

Aluminum Diecasting, Small Size and/or Low Complexity

C1.6

E1.4 Stamping & Forming, Medium-Large 

SizeStamping & Forming, Small-Medium SizeStamping & Forming, 2X Large Size

E1.3 Stamping & Forming, Large Size

Stamping & Forming, Terminals Electrical Terminals

E1.5 Stamping & Forming, Medium Size

Stamping & Forming, Extra Small Size 

E1.6

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 2 of 9 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

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Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

G. Machining 

G1. ≤4 Axis, Manual Load, CNC Horizontal Machining Center (X,Y,Z and Rotation "B"), General, Station Based

1 HS-7R - Pallet Size 2032X1016 mm, 10,000 lb 

Capacity (PC: 

1 Chip Removal CNC Machining, LS, HC $6

2 Work piece Envelop (Ø2450 x 1000 mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, LS, HC, 

PREM.

$7

3 Travel X,Y,Z (2134, 1676, 1524) & 360 Rotation 3 4 Dual Pallet Changer 4 5 38 Tool, Tool changer 5

1B 1 EC-630 - Pallet Size 630 mm square, 2645 lb Capacity 1 Chip Removal CNC Machining, MHC $5

2 Workpiece Envelop (Ø891 x 798mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, MHC, 

PREM.

$5

3 Travel X,Y,Z (1016, 838, 889) & 360 Rotation 34 Dual Pallet Changer 45 50 Tool, Tool changer 5

1B 1 EC-550 - Pallet Size 550 mm square, 2205 lb Capacity 1 Chip Removal CNC Machining, MC $4

2 Workpiece Envelop (Ø778 x 798mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, MC, PREM. $43 Travel X,Y,Z (762, 864, 813) & 360 Rotation 34 Dual Pallet Changer 45 40 Tool, Tool changer 5

1B 1 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity 1 Chip Removal CNC Machining, LMC $3

$

2 Workpiece Envelop (Ø500 x 762mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, LMC, 

PREM.

$3

3 Travel X,Y,Z (508,508,508) & 360 Rotation 34 Dual Pallet Changer 45 24 Tool, Tool changer 5

1B 1 EC-300 - Pallet Size 300 mm square, 550 lb Capacity 1 Chip Removal CNC Machining, LC $3

2 Workpiece Envelop (Ø381 x 572mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, LC, PREM. $3

3 Travel X,Y,Z (508,457,356) & 360 Rotation 3 Hydraulic Clamping4 Dual Pallet Changer 4 Tool Probing System5 24 Tool, Tool changer 5

G2. 5 Axis and/or Automatic Load CNC Horizontal Machining Center (X,Y,Z and Rotation "B", Tilt "A"), General, Station Based

1 HS-7R - Pallet Size 2032X1016 mm, 10,000 lb 

Capacity (PC: 

1 Chip Removal CNC Machining, LS, HC, 

Automatic Load

$9

2 Workpiece Envelop (Ø2450 x 1000 mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, LS, HC, 

Automatic Load, PREM.

$9

3 Travel X,Y,Z (2134, 1676, 1524), Rotation & Tilt 3 Hydraulic Clamping 

4 Dual Pallet Changer 4 Tool Probing System 

5 38 Tool, Tool changer 5 Robotic Part Load/Unload

1B 1 EC-630 - Pallet Size 630 mm square, 2645 lb Capacity 1 Chip Removal CNC Machining, MHC, 

Automatic Load

$6

2 Workpiece Envelop (Ø891 x 798mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, MHC, 

Automatic Load, PREM.

$7

3 Travel X,Y,Z (1016, 838, 889), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer 4 Tool Probing System5 50 Tool, Tool changer 5 Robotic Part Load/Unload

1B 1 EC-550 - Pallet Size 550 mm square, 2205 lb Capacity 1 Chip Removal CNC Machining, MC, 

Automatic Load

$5

2 Workpiece Envelop (Ø778 x 798mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, MC, 

Automatic Load, PREM.

$6

3 Travel X,Y,Z (762, 864, 813), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer 4 Tool Probing System5 40 Tool, Tool changer 5 Robotic Part Load/Unload

G2.1

Rear Covers - Block, Main Bearing Cap Brace

G1.5 CNC Machining, Small Size and/or 

Low Complexity

(7.5% Premium paid for machining aggressive materials)

G2.2 5 Axis and/or Auto Load, CNC 

Machining, Auto Load, Medium-Large Size and/or Moderate-High Complexity.

(7.5% Premium paid for machining aggressive materials)5 Axis and/or Auto Load, CNC Machining, Large Size and/or High Complexity(7.5% Premium paid for machining aggressive materials, i.e., Hypereutectic Aluminums)

G1.4G1.1 CNC Machining, Large Size and/or 

High Complexity

(7.5% Premium paid for machining aggressive materials, i.e., Hypereutectic Aluminums)

Supplier Machining of large complex castings, e.g. Engine BlocksExhaust Manifolds, Cylinder Head Covers, Front Cover

G1.2 CNC Machining, Medium-Large Size 

and/or Moderate-High Complexity.

(7.5% Premium paid for machining aggressive materials)

G2.3 5 Axis and/or Auto Load, 5 Axis CNC 

Machining, Auto Load, Medium Size and/or Moderate Complexity

(7.5% Premium paid for machining aggressive materials)

G1.3 CNC Machining, Medium Size and/or 

Moderate Complexity

(7.5% Premium paid for machining aggressive materials)CNC Machining, Small-Medium Size and/or Low-Moderate Complexity.(7.5% Premium paid for machining aggressive materials)

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 3 of 9 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

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Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

1B 1 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity 1 Chip Removal CNC Machining, LMC, 

Automatic Load

$4

2 Workpiece Envelop (Ø500 x 762mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, LMC, 

Automatic Load, PREM.

$4

3 Travel X,Y,Z (508,508,508), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer 4 Tool Probing System5 24 Tool, Tool changer 5 Robotic Part Load/Unload

1B 1 EC-300 - Pallet Size 300 mm square, 550 lb Capacity 1 Chip Removal CNC Machining, LC, 

Automatic Load

$3

2 Workpiece Envelop (Ø381 x 572mm) 2 Self-contained Coolant Delivery & Filtration CNC Machining, LC, 

Automatic Load, PREM.

$4

3 Travel X,Y,Z (508,457,356), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer 4 Tool Probing System5 24 Tool, Tool changer 5 Robotic Part Load/Unload

G3. CNC Rotary or Linear Transfer Machining Centers, Option #1 -> Stationary Part, Option #2 - Part Indexing Stations, Option #3 - Part Turning Stations, General, Station Based

1 Hydromat Trunnion V8 or V12 Type Equipment 1 Small Casting Applications, Forgings, 

Irregular Bar Stock Components, etc.

Rot./Lin. Trans. Machining Line, SP

$1

2 Max 12 Stations 2 Rot./Lin. Trans. Machining 

Line, SP, PREM.

$1

3 12 Max Horizontal & 6 Max Vertical Tooling Spindle 3 CNC Milling, LMC $14 Automated Part Flipping 45 Part is stationary fixtured/chucked, thus no indexing. 5 Custom application, fittings for brake tubes, 

oil lines etc

CNC Milling, SMS, LC $1

6 (Base Machine Cost 6 or less Stations, +5% Station) 6

7

1 Hydromat Index Chuck Machine V12 or V16 Type 

Equipment

1 Small Casting Applications, Forgings, 

Irregular Bar Stock Components, etc.

Rot./Lin. Trans. Machining Line, IP

$1

2 Max 16 Stations 2 Rot./Lin. Trans. Machining 

Line, IP, PREM.

$2

3 Horizontal & Vertical Tooling Spindle 34 Automated Part Flipping 45 Part Indexing Capabilities @ each machining station. 56 (Base Machine Cost 8 or less Stations, +5% Station) 6

7 71 Hydromat AT Advanced Technology Type Equipment 1 Rot./Lin. Trans. Machining 

Line, TP

$2

2 Max 10 Stations 2 Rot./Lin. Trans. Machining 

Line, TP, PREM.

$3

3 Horizontal & Vertical Tooling Spindle 3 CNC Milling, LS, HC $24 Automated Part Flipping 45 Part Turning Capabilities @ each machining station. 56 (Base Machine Cost 6 or less Stations, +5% Station) 6

7 7

G4. Customized Machining Equipment, High Volume, Finite Repetitive Operation, General, Station Based ( Categorized on Cost)

1 Rate based on $/Hour for a average station in a High 

Complexity Machining Center (i.e. 4 Axis). Add Number of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.

1 Dedicated Machining Center - 

Single Station, HC, Base

$6

2 Total Value of Equipment: $400-500K 2

3 Stations could be linked with additional machining 

and/or other assembly stations.

3

4 4 .5 5

1B 1 Rate based on $/Hour for a average station in a High 

Complexity Machining Center (i.e. 4 Axis). Add Number of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.

1 Dedicated Machining Center - 

Single Station, MHC, Base

$5

2 Total Value of Equipment: $300K-$400K 2

3 Stations could be linked with additional machining 

and/or other assembly stations.

3

4 45 5

G4.1 Tier 1/2 Dedicated Machining Station, 

Large Size and/or High Complexity

G3.2G4.2 Tier 1/2 Dedicated Machining Station, 

Medium-Large Size and/or ModerateHigh Complexity

G2.5G3.3G3.1G2.4 5 Axis and/or Auto Load, CNC 

Machining, Small-Medium Size and/or Low-Moderate Complexity.(7.5% Premium paid for machining aggressive materials)Automated Rotary or Linear Semi dedicated transfer machines. Part stationary fixtured/chucked(7.5% Premium paid for machining aggressive materials)Automated Rotary or Linear Semi dedicated transfer machines. Part Indexing capability @ each machining station.(7.5% Premium paid for machining aggressive materials)Automated Rotary or Linear Semi dedicated transfer machines. Part Turning or Indexing capability @ each machining station.(7.5% Premium paid for machining aggressive materials)

Small Casting Applications, Forgings, Irregular Bar Stock Components, etc. (Pistons)

5 Axis and/or Auto Load, CNC Machining, Small Size and/or Low Complexity

(7.5% Premium paid for machining aggressive materials)

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 4 of 9 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

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Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

1B 1 Rate based on $/Hour for a average station in a High 

Complexity Machining Center (i.e. 4 Axis). Add Number of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.

1 Dedicated Machining Center - 

Single Station, MC, Base

$4

2 Total Value of Equipment: $200K-300K 2

3 Stations could be linked with additional machining 

and/or other assembly stations.

3

4 45 5

1B 1 Rate based on $/Hour for a average station in a High 

Complexity Machining Center (i.e. 4 Axis). Add Number of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.

1 Dedicated Machining Center - 

Single Station, LMC, Base

$3

2 Total Value of Equipment: $100K-200K 2

3 Stations could be linked with additional machining 

and/or other assembly stations.

3

4 45 5

1B 1 Rate based on $/Hour for a average station in a High 

Complexity Machining Center (i.e. 4 Axis). Add Number of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.

1 Dedicated Machining Center - 

Single Station, LC, Base

$3

2 Total Value of Equipment: $0-$100K 2

3 Stations could be linked with additional machining 34 45 5

G5. Machining, Component Specific, Line Base Rate per Primary Equipment Count

1 Average cost per primary equipment using in machining 

process of Camshaft (e.g. establishing camshaft datum's, turning journals and grinding lobes)

1 Camshaft Machining 

Equipment

$5

2 2

3 34 45 5

1B H. CNC Turning

H1. CNC Turning, Auto Bar Feed (BF), Dual Axis (DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over base assumptions.

1 SL-40BB, Bar Capacity=Ø178mm 1 Lathe Work Gauging Probe CNC Turning, MLS, BF, DA $3

2 Max Cutting Diameter = Ø648mm, Max Cutting Length =1118 mm

2 Parts Catcher System 

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System 4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift 

5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-30BB, Bar Capacity=Ø102mm 1 Lathe Work Gauging Probe CNC Turning, MS, BF, DA $2

2 Max Cutting Diameter = Ø432mm, Max Cutting Length =864mm

2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-20BB, Bar Capacity=Ø64mm 1 Lathe Work Gauging Probe CNC Turning, SMS, BF, DA $2

2 Max Cutting Diameter = Ø262mm, Max Cutting Length =508mm

2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

G4.3 Tier 1/2 Dedicated Machining Station, 

Medium Size and/or Moderate Complexity

Connecting Rods, Head Riser & Gate Cutoff and Debarring

G4.5 Tier 1/2 Dedicated Machining Station, 

Small Size and/or Low ComplexityAverage Cost per Hour per Piece of primary Camshaft Machining Equipment

Camshafts

G4.4 Tier 1/2 Dedicated Machining Station, 

Small-Medium Size and/or LowModerate Complexity

Calculated using( H.7.3) CNC Turning, Auto Load, Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, Small-Medium Size Parts ($32.17/Hour) * 1.70Factor (Ratio of primary to secondary support equipment costs for cylinder head line)

G5.1

H1.1

CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Medium-Large Size Parts

H1.2

CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Medium Size Parts

H1.3

CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Small-Medium Size Parts

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 5 of 9 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

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Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

1 SL-10BB, Bar Capacity=Ø51mm 1 Lathe Work Gauging Probe CNC Turning, SS, BF, DA $2

2 Max Cutting Diameter = Ø279mm, Max Cutting Length =356mm

2 Parts Catcher System CNC Turning, LC $2

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

H2.

1 SL-40BB, Bar Capacity=Ø178mm 1 Lathe Work Gauging Probe CNC Turning, MLS, BF, QA $5

2 Max Cutting Diameter = Ø648mm, Max Cutting Length =1118 mm

2 Automated part unload 

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System 

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift 

5 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-30BB, Bar Capacity=Ø102mm 1 Lathe Work Gauging Probe CNC Turning, MS, BF, QA $4

2 Max Cutting Diameter = Ø432mm, Max Cutting Length =864mm

2 Automated part unload

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-20BB, Bar Capacity=Ø64mm 1 Lathe Work Gauging Probe CNC Turning, SMS, BF, QA $3

2 Max Cutting Diameter = Ø262mm, Max Cutting Length =508mm

2 Automated part unload

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-10BB, Bar Capacity=Ø51mm 1 Lathe Work Gauging Probe CNC Turning, SS, BF, QA $3

2 Max Cutting Diameter = Ø279mm, Max Cutting Length =356mm

2 Automated part unload. CNC Turning, MC $3

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System CNC Turning, HC No Lon

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

H3. Double Sided (DS) Part, CNC Turning, Auto Bar Feed (BF), Dual Axis (DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over base assumptions.

1 THEO-TL-35BB, Bar Capacity=Ø178mm 1 Lathe Work Gauging Probe DS-CNC Turning, MLS, BF, DA $3

2 Max Cutting Diameter = Ø648mm, Max Cutting Length =1118 mm

2 Parts Catcher System 

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System 4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift 5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter1 TL-25 BB, Bar Capacity=Ø102mm 1 Lathe Work Gauging Probe DS-CNC Turning, MS, BF, DA $3

2 Max Cutting Diameter = Ø406mm, Max Cutting Length =864mm

2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 TL-15BB, Bar Capacity=Ø64mm 1 Lathe Work Gauging Probe DS-CNC Turning, SMS, BF, DA $2

2 Max Cutting Diameter = Ø208mm, Max Cutting Length =445mm

2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

H3.3

Double Sided Part, CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Small-Medium Size Parts

H3.2

Double Sided Part, CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Medium Size Parts

H3.1

Double Sided Part, CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Medium-Large Size Parts

H1.4

CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Small Size Parts

H2.1

CNC Turning, Bar Fed, Machining in "C" ,"X", "Y" and "Z" Axis Only, Automated Unload, Medium-Large Size Parts

CNC Turning, Auto Bar Feed (BF), Quad Axis (QA) Machining ("C" , "X", "Y" and "Z" Axis), Automated Unload, General, Station Based with multiplier for added complexity over base assumptions.

H2.3

CNC Turning, Bar Fed, Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, Small-Medium Size Parts

H2.2

CNC Turning, Bar Fed, Machining in "C" ,"X", "Y"and "Z" Axis Only, Automated Unload, Medium Size Parts

H2.4

CNC Turning, Bar Fed, Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, Small Size Parts

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APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

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Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

1 THEO-TL-05BB, Bar Capacity=Ø51mm 1 Lathe Work Gauging Probe DS-CNC Turning, SS, BF, DA $2

2 Max Cutting Diameter = Ø279mm, Max Cutting Length =356mm

2 Parts Catcher System S-CNC Turning, LC $2

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

H4.

1 THEO-TL-35BB, Bar Capacity=Ø178mm 1 Lathe Work Gauging Probe DS-CNC Turning, MLS, BF, QA $5

2 Max Cutting Diameter = Ø648mm, Max Cutting Length =1118 mm

2 Automated part unload 

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System 

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift 5 5 High-Pressure Coolant, 1000 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter1 TL-25 BB, Bar Capacity=Ø102mm 1 Lathe Work Gauging Probe DS-CNC Turning, MS, BF, QA $4

2 Max Cutting Diameter = Ø406mm, Max Cutting Length =864mm

2 Automated part unload

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 Transfer Time to Sub-spindle 8 Seconds 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 TL-15BB, Bar Capacity=Ø64mm 1 Lathe Work Gauging Probe DS-CNC Turning, SMS, BF, QA $4

2 Max Cutting Diameter = Ø208mm, Max Cutting Length =445mm

2 Automated part unload

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 Transfer Time to Sub-spindle 8 Seconds 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 THEO-TL-05BB, Bar Capacity=Ø51mm 1 Lathe Work Gauging Probe DS-CNC Turning, SS, BF, QA $3

2 Max Cutting Diameter = Ø279mm, Max Cutting Length =356mm

2 Automated part unload. S-CNC Turning, MC $3

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System S-CNC Turning, HC No Lon

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

H5.

1 Hydromat Rotary Transfer Machine - Max 16 Station 1 MS-16Max, CNC Turning, 

SMS, BF, QA

$2

2 Bar Size = Ø44 and Length 150 mm 2 RTM Turning, HC, PP, Base $23 Up to 16 Horizontal & 8 Vertical Tooling Spindle 34 Automated Part Flipping 45 (Base Machine Cost 12 Stations, +10% Station) 5

6 67 71 Hydromat Rotary Transfer Machine - Max 12 Station 1 MS-12Max, CNC Turning, 

SMS, BF, QA

$1

2 Bar Size = Ø25 and Length 100 mm 2 RTM Turning, MC, PP, Base $13 Up to 12 Horizontal & 6 Vertical Tooling Spindle 34 Automated Part Flipping 45 (Base Machine Cost 8 Stations, +10% Station) 5

6 67 7

H3.4

Double Sided Part, CNC Turning, Bar Fed, Machining in "C" and "Z" Axis Only, Small Size Parts

H5.2 Multi Station -12, CNC Turning, Auto 

Bar Fed, Machining in "C" ,"X", "Y" and "Z" Axis Only, Double Sided, Automated Unload, Small-Medium Size Parts

H5.1 Multi Station -16, CNC Turning, Auto 

Bar Fed, Machining in "C" ,"X", "Y" and "Z" Axis Only, Double Sided, Automated Unload, Small-Medium Size Parts

Double Sided (DS) Part, CNC Turning, Auto Bar Feed (BF), Quad Axis (QA) Machining ("C" , "X", "Y" and "Z" Axis), Automated Unload, General, Station Based with multiplier for added complexity over base assumptions.

H4.1

Double Sided Part, CNC Turning, Bar Fed, Machining in "C" ,"X", "Y" and "Z" Axis Only, Automated Unload, Medium-Large Size Parts

H4.2

Double Sided Part, CNC Turning, Bar 

Fed, Machining in "C" ,"X", "Y"and "Z" Axis Only, Automated Unload, Medium Size Parts

H4.3

Double Sided Part, CNC Turning, Bar Fed, Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, SmallMedium Size PartsMulti Station (MS), CNC Turning, Auto Bar Feed (BF), Quad Axis (QA) Machining ("C" , "X", "Y" and "Z" Axis), Double Sided (DS) Part, Automated Unload, General, Station Based with multiplier for added complexity over base assumptions.

H4.4

Double Sided Part CNC Turning, Bar 

Fed, Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, Small Size Parts

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 7 of 9 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

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Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

1 Hydromat Inline Standard 8 - Max 8 Stations 1 $2 Bar Size = Ø25 and Length 550 mm 23 Bar Stock or Blanks 34 45 56 67 71 THEO-ZPS 842, 8 Station Turning Machine 1 Lathe Work Gauging Probe MS-8Max, CNC Turning, SMS, BF, QA $2

2 Bar Size = Ø42 and Length 125 mm 2 Automated part unload 3 16 Station Turret: Average (8 Fixed, 4 Axial Live Tools and 4 Radial Live Tools)

3 Tool Presetter System 

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift 5 5 High-Pressure Coolant, 1000 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter1 THEO-ZPS 642, 6 Station Turning Machine 1 Lathe Work Gauging Probe MS-6Max, CNC Turning, SMS, BF, QA $1

2 Bar Size = Ø42 and Length 125 mm 2 Automated part unload.3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Tool Presetter System

4 Automatic Bar Feeder 4 Chip Auger with Mobile Chip Lift

5 5 High-Pressure Coolant, 1000 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

H6.

1 SL-40BB, Chuck Capacity=Ø178mm 1 Lathe Work Gauging Probe CNC Turning, MLS, ML, DA $3

2 Max Cutting Diameter = Ø648mm, Max Cutting Length =1118 mm

2 Parts Catcher System 

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System 4 4 Chip Auger with Mobile Chip Lift 

5 5 High-Pressure Coolant, 300 psi (21 bar)

6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-30BB, Chuck Capacity=Ø102mm 1 Lathe Work Gauging Probe CNC Turning, ML, ML, DA $2

2 Max Cutting Diameter = Ø432mm, Max Cutting Length =864mm

2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-20BB, Chuck Capacity=Ø64mm 1 Lathe Work Gauging Probe CNC Turning, SMS, ML, DA $2

2 Max Cutting Diameter = Ø262mm, Max Cutting Length =508mm

2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter1 SL-10BB, Chuck Capacity=Ø51mm 1 Lathe Work Gauging Probe CNC Turning, SS, ML, DA $1

2 Max Cutting Diameter = Ø279mm, Max Cutting Length =356mm

2 Parts Catcher System

3 12 Station Turret, Bolt on Tooling 3 Tool Presetter System

4 4 Chip Auger with Mobile Chip Lift5 5 High-Pressure Coolant, 300 psi (21 bar)6 6 Auxiliary Coolant Filter System, 25-micron filter

Odd Form Part, CNC Turning, Manual Load (ML), Axis (DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over base assumptions. Category for odd form components, e.g. pre-machine bar stock, forged parts, diecast

H6.4

CNC Turning, Manual Load, Machining in "C" and "Z" Axis Only, Small Size Parts

H6.3

CNC Turning, Manual Load, Machining in "C" and "Z" Axis Only, Small-Medium Size Parts

H6.2

CNC Turning, Manual Load, Machining in "C" and "Z" Axis Only, Medium Size Parts

H6.1

CNC Turning, Manual Load, Machining in "C" and "Z" Axis Only, Medium-Large Size Parts

H5.3 Multi Station -8, Long Part, CNC 

Turning, Auto Bar Fed, Machining in "C" ,"X", "Y" and "Z" Axis Only, Double Sided, Automated Unload, Small-Medium Size Parts

H5.4

Multi Station -8, CNC Turning, Auto Bar Fed, Machining in "C" ,"X", "Y" and "Z" Axis Only, Double Sided, Automated Unload, Small-Medium Size Parts

H5.5

Multi Station-6, CNC Turning, Auto Bar Fed, Machining in "C" ,"X", "Y" and "Z" Axis Only, Double Sided, Automated Unload, Small-Medium Size Parts

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 8 of 9 
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt 

Activ

2

Cat. Item Burden Title Primary Processing Equipment Secondary Process Equipment Product Examples Burden Classification

A. Thermoplastic 

B. Thermoset

C. Casting 

D. Forging

H. Turning

G. Machining

F. Powder Metal J. Grinding

E. Stamping & Forming

M. Plating

R. OEM Assembly

S.

Q. OEM Machining T.

N. Washing

L. Heat Treat P. T1/T2/T3 Ass'y

K. Balancing U.

V.

W. 

X.

Y. Miscellaneous

Z. 

H7.

1 SL-40BB, Chuck Capacity=Ø178mm 1 Lathe Work Gauging Probe CNC Turning, MLS, AL, QA $4

2 Max Cutting Diameter = Ø648mm, Max Cutting Length =1118 mm

2 Tool Presetter System 

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Chip Auger with Mobile Chip Lift $8

4 Automatic Part Load & Unload System 4 High-Pressure Coolant, 1000 psi (21 bar) 

5 5 Auxiliary Coolant Filter System, 25-micron filter

6 61 SL-30BB, Chuck Capacity=Ø102mm 1 Lathe Work Gauging Probe CNC Turning, MS, AL, QA $3

2 Max Cutting Diameter = Ø432mm, Max Cutting Length =864mm

2 Tool Presetter System

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Chip Auger with Mobile Chip Lift

4 Automatic Part Load & Unload System 4 High-Pressure Coolant, 1000 psi (21 bar)

5 5 Auxiliary Coolant Filter System, 25-micron filter6 61 SL-20BB, Chuck Capacity=Ø64mm 1 Lathe Work Gauging Probe CNC Turning, SMS, AL, QA $3

2 Max Cutting Diameter = Ø262mm, Max Cutting Length =508mm

2 Tool Presetter System

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Chip Auger with Mobile Chip Lift

4 Automatic Part Load & Unload System 4 High-Pressure Coolant, 1000 psi (21 bar)

5 5 Auxiliary Coolant Filter System, 25-micron filter6 61 SL-10BB, Chuck Capacity=Ø51mm 1 Lathe Work Gauging Probe CNC Turning, SS, AL, QA $2

2 Max Cutting Diameter = Ø279mm, Max Cutting Length =356mm

2 Tool Presetter System

3 12 Station Turret: Average (6 Fixed, 3 Axial Live Tools and 3 Radial Live Tools)

3 Chip Auger with Mobile Chip Lift

4 Automatic Part Load & Unload System 4 High-Pressure Coolant, 1000 psi (21 bar)

5 5 Auxiliary Coolant Filter System, 25-micron filter6 6

Q. OEM Machining

Q1. OEM Machining, Component Specific, Line Based using Multiplier X number of pieces of primary equipment

1 1 CNC Machining, Crankshafts, 

OEM

$6

2 23 34 45 51 4 & 5 Axis CNC Machines, or 1 Automation (Gantry robot w/automation) per CNC 

machining operation

CNC Machining, Cylinder Block, OEM

$8

2 Custom Machining Centers, or 2 Main Line automation (gantry robot & automation) per 

operation

3 In-line Washers, or 3 Coolant System, Mist Collection, Process Water & 

Waste, Misc. Department Equipment

4 In-Line Inspection & Gauging 4 Production Floor CMM 5 51 4 & 5 Axis CNC Machines, or 1 Automation (Gantry robot w/automation) per CNC 

machining operation

CNC Machining, Cylinder Head, OEM

$7

2 Custom Machining Centers, or 2 Main Line automation (gantry robot & automation) per 

operation

3 Head Assembly Equipment (on Machining line), or 3 Coolant System, Mist Collection, Process Water & 

Waste, Misc. Department Equipment

4 In-line Washers, or 4 Production Floor CMM 

5 In-Line Inspection & Gauging 5

H7.4

CNC Turning, Auto Load, Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, Small Size Parts

H7.3

CNC Turning, Auto Load, Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, Small-Medium Size Parts

H7.2

CNC Turning, Auto Load, Machining in "C" ,"X", "Y"and "Z" Axis Only, Automated Unload, Medium Size Parts

H7.1

CNC Turning, Auto Load, Machining in "C" ,"X", "Y" and "Z" Axis Only, Automated Unload, Medium-Large Size Parts

Odd Form, CNC Turning, Auto Load (AL) and Unload, Quad Axis (QA) Machining ("C" , "X", "Y" and "Z" Axis), General, Station Based with multiplier for added complexity over base assumptions. Category for odd form components, e.g. pre-machine bar stock, for

Q1.1 Crankshaft Machining Calculated using( H.7.3) CNC Turning, Auto Load, 

Machining in "C","X", "Y" and "Z" Axis Only, Automated Unload, Medium Size Parts ($39.48/Hour) * 1.70 Factor(Ratio of primary to secondary support equipment costs for cylinder head line)

Q1.2 Cylinder Block Machining Line 

(Average cost per primary piece of manufacturing equipment on a cylinder block machining line)

Q1.3 Cylinder Head Machining Line 

(Average cost per primary piece of manufacturing equipment on a cylinder head machining line)

Average cost per primary equipment using in machining process of crankshaft (e.g. Machining Center for Datums, Turn-Turn broach, OD Mill, Multi-wheel Main Grinder, Pin Grinder etc)

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.3, Page 9 of 9 
APPENDIX E.4

 Manufacturing Overhead Calculator Template

Appendix E.4

Printed: 12/9/2009

A. General Manufacturing Overhead Information

Burden Title: Burden Classification: Injection Molding, Medium Size and/or Moderate Complexity 

Burden Primary Process Equipment Description: Injection Molding Station, 500T Press

Estimated Production Facility Size: 1.50E+05 Square Footage Options ( 1.5E5, 2.5E5, 5.0E5, 7.5E5, 10E5, 20E5)

Primary Process Equipment Life Expectancy: 12 Years

Process Support Equipment Life Expectancy: 12 Years

General Plant & Office Life Expectancy: 10 Years

Yearly Operating Capacity: 4700 Hours

Operation Efficiency 85.00% Percent

Production Usage Efficiency 81.99% Percent

Cost To Borrow Money/Annual 8.00% Percent

B. Primary Processing Equipment Yearly Rate Expense 

Frequency

% of Primary 

Equip. Exp. Value

B.1 $ 260,000.00

B.2 $ -

B.3 $ 260,000.00

B.4 5.57% 1 5.57% $ 14,482.00

B.5 $ 274,482.00

B.6 1.00% 1 1.00% 2,600.00 $ 

B.7 12.00% 1 12.00% 31,200.00 $ 

B.8 1.00% 1 1.00% 2,600.00 $ 

B.9 5.00% 1 5.00% 13,000.00 $ 

B.10 $ 323,882.00

B.11 8% 1 NA $ 42,070.43

B.12 0.66% 12 0.66% 1,708.31 $ 

B.13 0.60% 12 0.60% 1,560.00 $ 

B.14 3.00% 12 3.00% 7,800.00 $ 

B.15 $ 53,138.74

C. Yearly Rate Expense 

Frequency

% of Primary 

Equip. Exp. Value

C.1 $ 29,950.00

C.2 $ -

C.3 $ 29,950.00

C.4 5.57% 1 5.57% $ 1,668.22

C.5 $ 31,618.22

C.6 1.00% 1 1.00% 299.50 $ 

C.7 12.00% 1 12.00% 3,594.00 $ 

C.8 1.00% 1 1.00% 299.50 $ 

C.9 5.00% 1 5.00% 1,497.50 $ 

C.10 $ 37,308.72

C.11 8% 1 NA $ 4,846.19

C.12 0.66% 12 0.66% 196.78 $ 

C.13 0.60% 12 0.60% 179.70 $ 

C.14 3.00% 12 3.00% 898.50 $ 

C.15 $ 6,121.17

D. Value

D.1 $ 59,259.91

D.2 $ 1,185.20

D.3 $ 237.04

D.4 $ 118.52

D.5 $ 118.52

D.6 $ 118.52

D.7 General Quality Lab Equipment $ 237.04

D.8 Office Equipment $ 592.60

D.9 $ 2,607.44

1.00%

0.20%

0.20%

0.20%

0.40%

% of Primary & Process 

Support Equipment Costs

 NA 

2.00%

0.40%

4.40%

Process Support Equipment Cost Including Sales Tax

General Plant & Office Hardware/Equipment 

Set-up & Run-offs (Power on to Production Part Approval Process PPAP) (one time expense, value default 5%)

Process Support Equipment Sub-total Including Freight, Installation, Set-up and Run-off. (C.5+C.6+C.7+C.8+C.9)

Annual Financing Expense for Process Support Equipment Sub-total (C.10)

Installation (one time expense)

Process Support Equipment Design (Customized equipment/machinery or highly complex integration of commodity 

based equipment)

Process Support Equipment Cost (C.1+C.2)

Process Support Equipment Build

Annual Financing Expense for Primary Process Equipment Sub-total (B.10)

Equipment Insurance Cost - Fire and General

Installation to Power On (one time expense)

Set-up & Run-offs (Power on to Production Part Approval Process PPAP) (one time expense, value default 5%)

Spare Parts-Maintenance & Repair, includes perishable goods (default 3%/year)

Primary Process Equipment Sub-total Including Freight, Installation, Set-up and Run-off. (B.5+B.6+B.7+B.8+B.9)

Personal Property Tax 

Millwright, Electrician, Plumbing Tool Crib

Process Support Equipment - Process Dependent (Required to carry-out primary process)

Sales Tax (C.4*Rate)

Personal Property Tax 

Equipment Insurance Cost - Fire and General

Freight (one time expense)

Installation (one time expense)

Installation to Power On (one time expense)

Production/Quality Communication and Data Tracking & Storage

Total Primary Equipment Costs per Annum

Sum of Total Primary Process Equipment Costs/Year (B.15) & Process Support Equipment Costs/Year (C.15)

Total General Plant & Office Hardware/Equipment Costs per Year

General Material Handling Equipment (e.g. Tow-Motors, Cranes, Fork Lifts)

Plant Cleaning Equipment

Spare Parts-Maintenance & Repair, includes perishable goods (default 3%/year)

Storage, Shipping and Receiving Equipment

Total Process Support Equipment Costs per Annum

Primary Process Equipment Build

Primary Process Equipment Design (Customized equipment/machinery or highly complex integration of commodity 

based equipment)

Sales Tax (B.4*Rate)

Freight (one time expense)

Primary Process Equipment Cost (B.1+B.2)

Primary Process Equipment Cost Including Sales Tax

Utilization Rates Fed Reserve Rate by NAIC (2002-2007):

>Primary metal 79.87%,

>Fabricate Metal Products 75.19%,

>Electrical 78.99%,

>Motor Vehicle Parts 75.66%,

>Chemical (paints resins) 76.63%

>Plastic & Rubbers 81.99%

File:Final Report Costing Databases 120809.xls

EPA Contract: EP-C-07-069 WA1-3 E.4, Page 1 of 3 Form Author: G. Kolwich

(248)373-6000 Ext. 2411
APPENDIX E.4

 Manufacturing Overhead Calculator Template

Appendix E.4

Printed: 12/9/2009

A. General Manufacturing Overhead Information

Burden Title: Burden Classification: Injection Molding, Medium Size and/or Moderate Complexity 

Burden Primary Process Equipment Description: Injection Molding Station, 500T Press

Estimated Production Facility Size: 1.50E+05 Square Footage Options ( 1.5E5, 2.5E5, 5.0E5, 7.5E5, 10E5, 20E5)

Primary Process Equipment Life Expectancy: 12 Years

Process Support Equipment Life Expectancy: 12 Years

General Plant & Office Life Expectancy: 10 Years

Yearly Operating Capacity: 4700 Hours

Operation Efficiency 85.00% Percent

Production Usage Efficiency 81.99% Percent

Cost To Borrow Money/Annual 8.00% Percent

Utilization Rates Fed Reserve Rate by NAIC (2002-2007):

>Primary metal 79.87%,

>Fabricate Metal Products 75.19%,

>Electrical 78.99%,

>Motor Vehicle Parts 75.66%,

>Chemical (paints resins) 76.63%

>Plastic & Rubbers 81.99%

E.

(Cost/ 

Square Foot)/

year

% of Primary 

& Process 

Support 

Equipment 

Area

Total Square 

Feet Value

E.1 $ 11.50 NA 418 $ 4,807.00

E.2 $ 11.50 NA 321 $ 3,691.50

E.3 $ 11.50 75% 554.25 6,373.88 $ 

E.4 1293.25 14,872.38 $ 

F.

Utility Units Unit Cost

Input Cost/Hour Input Cost/Hour Percent 

Contribution Cost/Hour

F.1 Electricity Kilowatt Hour $ 0.0717 129.5 $9.29 49 $3.51 0% $ -

F.2 Natural 

Gas Cubic Feet $ 0.01 0 $0.00 0 $0.00 0% $ -

F.3 Coke Ton $ 190.00 0 $0.00 0 $0.00 0% $ -

F.4 Fuel Oil Barrel $ 46.40 0 $0.00 0 $0.00 0% $ -

F.5 Water Gallons $ 0.00 0 $0.00 0 $0.00 0% $ -

F.6 Compressed 

Air CFM $ 0.025 0 $0.00 0 $0.00 0% $ -

F.7 Subtotals $9.29 $3.51 $0.00

F.8 $12.80

G.

Est. Hourly 

Employees Est. Salary Employees

G.1 109 13 1293 6,625.15 $ 

G.2 182 22 0 - $ 

G.3 365 44 0 - $ 

G.4 547 66 0 - $ 

G.5 730 88 0 - $ 

G.6 1460 175 0 - $ 

G.7 $ 6,625.15

$9.29 

$13.76 

Average Salary Contribution 

per Square Foot

Enter equipment square 

footage usage (E.4) in 

corresponding overall 

estimated facility square 

General Plant & Office Utility 

Usage 

$5.12 

$6.00 

$7.05 

$8.16 

Total Plant Salary Contribution to Manufacturing Overhead/Year

750,000

1,000,000

2,000,000

Estimated Facility Square Footage 

150,000

250,000

500,000

Plant Salary Contribution to Manufacturing Overhead (Note, does not include, direct, indirect or Maintenance, 

Repair or Other Labor)

Supporting Process 

Equipment Utility Usage

Total Process Support Equipment Floor Space Allocation: 

( Equipment Foot Print + 3 ft each side)

General Plant & Office Equipment/Hardware Floor Space 

Total utilities expense/hour for all Primary and Supporting Process Equipment

Primary Process Equipment Usage

Total Facilities Costs per Year

Utilities for Primary Process Equipment, Process Support Equipment & General Plant and Office 

Hardware/Equipment.

Total Primary Processing Equipment Floor Space Allocation

( Equipment Foot Print + 3 ft each side)

Facilities Cost/Floor Space Includes (Cost/Square Foot) -> Primary Process Equipment, Process Support 

Equipment, & General Plant Office Hardware/Equipment 

Facility costs in Section D 

cover general plant and 

office utility usage expenses.

File:Final Report Costing Databases 120809.xls

EPA Contract: EP-C-07-069 WA1-3 E.4, Page 2 of 3 Form Author: G. Kolwich

(248)373-6000 Ext. 2411
APPENDIX E.4

 Manufacturing Overhead Calculator Template

Appendix E.4

Printed: 12/9/2009

A. General Manufacturing Overhead Information

Burden Title: Burden Classification: Injection Molding, Medium Size and/or Moderate Complexity 

Burden Primary Process Equipment Description: Injection Molding Station, 500T Press

Estimated Production Facility Size: 1.50E+05 Square Footage Options ( 1.5E5, 2.5E5, 5.0E5, 7.5E5, 10E5, 20E5)

Primary Process Equipment Life Expectancy: 12 Years

Process Support Equipment Life Expectancy: 12 Years

General Plant & Office Life Expectancy: 10 Years

Yearly Operating Capacity: 4700 Hours

Operation Efficiency 85.00% Percent

Production Usage Efficiency 81.99% Percent

Cost To Borrow Money/Annual 8.00% Percent

Utilization Rates Fed Reserve Rate by NAIC (2002-2007):

>Primary metal 79.87%,

>Fabricate Metal Products 75.19%,

>Electrical 78.99%,

>Motor Vehicle Parts 75.66%,

>Chemical (paints resins) 76.63%

>Plastic & Rubbers 81.99%

H.

Utility Rate 

Contribution 

(F.8)

Total

H.1 12.798 30.54 $ 

H.2 14.718 35.12 $ 

H.3 14.718 38.79 $ 

H.4 $ 38.79

Note: The final rate for "Injection Molding, Medium Size and/or Moderate Complexity" is calculated by taking the hourly rates for equipment within this grouping (i.e.400-800 Ton 

Presses) and calculating the group average.

Burden Rate "Minus" Utility 

Rate Contribution

Hourly Burden Rate loaded in Burden Database

Total Hourly Rate based on 100% efficiency and utilization

Total Hourly Rate base on defined efficiency and 100% utilization

Total Hourly Rate base on defined efficiency and utilization $24.07 

$17.74 

$20.40 

Calculated Hourly Burden Rate at defined Efficiency and Utilization 

File:Final Report Costing Databases 120809.xls

EPA Contract: EP-C-07-069 WA1-3 E.4, Page 3 of 3 Form Author: G. Kolwich(248)373-6000 Ext. 2411
APPENDIX E.5 Mark-up Rate Database Excerpt 

Production Year/Case Study End Item Scrape Average Annual Adjustment Factor (AAF) Selling, General, and Administrative (SG&A), Average Annual AdjustProfit, Average Annual Adjustment Factor (AAF) 

TOP BOTTOM ED&T/R&D, Average Annual Adjustment Factor (AAF) 

End Item 

Scrap,

Active 

Rate

SG&A, 

Active 

Rate

Profit,

Active 

Rate

ED&T/ 

R&D, 

Active 

Rate

End Item 

Scrap 

Rate, 

Baseline

SG&A 

Rate,

 Baseline

Profit 

Rate,

Baseline

ED&T/ 

R&D 

Rate, 

Baseline

End 

Item 

Scrap, 

AAF

SG&A,

AAF

Profit, 

AAF

E

R

2020 2008 2008 2008

A. T2/T3 THERMOPLASTIC PROCESSING

1 Large Size, High Complexity 1 T2/T3 Inject. Mold, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Inject. Mold, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Inject. Mold, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

B. T2/T3 THERMOSET PROCESSING

1 Large Size, High Complexity 1 T2/T3 Comp./Ext. Mold, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Comp./Ext. Mold, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Comp./Ext. Mold, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

C. T2/T3 CASTING PROCESS

1 Large Size, High Complexity 1 T2/T3 Diecast, LSHC 5.00% 7.00% 8.00% 2.00% 5.00% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Diecast, MSMC 5.00% 6.50% 6.00% 1.00% 5.00% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Diecast, SSLC 5.00% 6.00% 4.00% 0.00% 5.00% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Large Size, High Complexity 1 T2/T3 Sand Cast, LSHC 5.00% 7.00% 8.00% 2.00% 5.00% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Sand Cast, MSMC 5.00% 6.50% 6.00% 1.00% 5.00% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Sand Cast, SSLC 5.00% 6.00% 4.00% 0.00% 5.00% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

C3.3

Sand Casting,(Gravity and Low Pressure Casting)(Cast Iron(s), Steel, Aluminum)

C3.2

Sand Casting,(Gravity and Low Pressure Casting)(Cast Iron(s), Steel, Aluminum)

C3.1

Sand Casting,(Gravity and Low Pressure Casting)(Cast Iron(s), Steel, Aluminum)

C1.3 Diecasting (Aluminum, Magnesium, Zinc)C1.2 Diecasting (Aluminum, Magnesium, Zinc)C1.1 Diecasting (Aluminum, Magnesium, Zinc)

B1.3 Compression and Extrusion Molding of Thermosetting PolymersB1.2 Compression and Extrusion Molding of Thermosetting PolymersB1.1 Compression and Extrusion Molding of Thermosetting Polymers

Injection Molding

Item

Supplier/OEM Classification 

(Based On Manufacturing 

Overhead Categories)

Injection Molding

OEM or Supplier 

Classification

A1.3

Supplier/OEM Size & 

Complexity Description Cat.

A1.1 Injection MoldingA1.2

A. T2/T3 ThermoPlast.

B. T2/T3 Thermoset

C. T2/T3 Casting 

D. T2/T3 Forging

H. T2/T3 Heat TreatG. T2/T3 Machining

F. T2/T3 Powder Metal I. T2/T3 Plating

E. T2/T3 Stamp-Form

L.

P. OEM Assembly

Q.

O. Z. MISC

M.

K. T2/T3 Misc. N. T1 Assembly

J. T2/T3Assembly

File: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.5, Page 1 of 5 
APPENDIX E.5 Mark-up Rate Database Excerpt 

Production Year/Case Study End Item Scrape Average Annual Adjustment Factor (AAF) Selling, General, and Administrative (SG&A), Average Annual AdjustProfit, Average Annual Adjustment Factor (AAF) 

TOP BOTTOM ED&T/R&D, Average Annual Adjustment Factor (AAF) 

End Item 

Scrap,

Active 

Rate

SG&A, 

Active 

Rate

Profit,

Active 

Rate

ED&T/ 

R&D, 

Active 

Rate

End Item 

Scrap 

Rate, 

Baseline

SG&A 

Rate,

 Baseline

Profit 

Rate,

Baseline

ED&T/ 

R&D 

Rate, 

Baseline

End 

Item 

Scrap, 

AAF

SG&A,

AAF

Profit, 

AAF

E

R

2020 2008 2008 2008

Item

Supplier/OEM Classification 

(Based On Manufacturing 

Overhead Categories)

OEM or Supplier 

Classification

Supplier/OEM Size & 

Complexity Description Cat.

A. T2/T3 ThermoPlast.

B. T2/T3 Thermoset

C. T2/T3 Casting 

D. T2/T3 Forging

H. T2/T3 Heat TreatG. T2/T3 Machining

F. T2/T3 Powder Metal I. T2/T3 Plating

E. T2/T3 Stamp-Form

L.

P. OEM Assembly

Q.

O. Z. MISC

M.

K. T2/T3 Misc. N. T1 Assembly

J. T2/T3Assembly

1 Large Size, High Complexity 1 T2/T3 Invest. Cast, LSHC 5.00% 7.00% 8.00% 2.00% 5.00% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Invest. Cast, MSMC 5.00% 6.50% 6.00% 1.00% 5.00% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Invest. Cast, SSLC 5.00% 6.00% 4.00% 0.00% 5.00% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

D. T2/T3 FORGING PROCESS

1 Large Size, High Complexity 1 T2/T3 Forge, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Forge, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Forge, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 2 2 3 3 4 4 5 51 Large Size, High Complexity 1 T2/T3 Cold Forge, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Cold Forge, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Cold Forge, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

E. T2/T3 STAMPING & FORMING PROCESS

1 Large Size, High Complexity 1 T2/T3 Stamp/Form, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Stamp/Form, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Stamp/Form, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

E1.3 Stamping & Forming,E1.1 Stamping & Forming,

D2.3 Cold Forgings, Cold Heading, Coining, Thread Rolling, etc.,D2.2D2.1

Cold Forgings, Includes Cold Bending, Cold Drawing, Extrusions, Etc.,Cold Forgings, Includes Cold Bending, Cold Drawing, Extrusions, Etc.,

D1.3D1.1 Impression/Close Die Forging,C4.3

Investment Casting, Great for Casting High Temp, Complex parts in aluminum alloys, bronze alloys, magnesium alloys, cast iron, stainless steel and tool steel.

D1.2 Impression/Close Die Forging,C4.1

Investment Casting, Great for Casting High Temp, Complex parts in aluminum alloys, bronze alloys, magnesium alloys, cast iron, stainless steel and tool steel.

C4.2

Investment Casting, Great for Casting High Temp, Complex parts in aluminum alloys, bronze alloys, magnesium alloys, cast iron, stainless steel and tool steel.Impression/Close Die Forging,

E1.2 Stamping & Forming,

File: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.5, Page 2 of 5 
APPENDIX E.5 Mark-up Rate Database Excerpt 

Production Year/Case Study End Item Scrape Average Annual Adjustment Factor (AAF) Selling, General, and Administrative (SG&A), Average Annual AdjustProfit, Average Annual Adjustment Factor (AAF) 

TOP BOTTOM ED&T/R&D, Average Annual Adjustment Factor (AAF) 

End Item 

Scrap,

Active 

Rate

SG&A, 

Active 

Rate

Profit,

Active 

Rate

ED&T/ 

R&D, 

Active 

Rate

End Item 

Scrap 

Rate, 

Baseline

SG&A 

Rate,

 Baseline

Profit 

Rate,

Baseline

ED&T/ 

R&D 

Rate, 

Baseline

End 

Item 

Scrap, 

AAF

SG&A,

AAF

Profit, 

AAF

E

R

2020 2008 2008 2008

Item

Supplier/OEM Classification 

(Based On Manufacturing 

Overhead Categories)

OEM or Supplier 

Classification

Supplier/OEM Size & 

Complexity Description Cat.

A. T2/T3 ThermoPlast.

B. T2/T3 Thermoset

C. T2/T3 Casting 

D. T2/T3 Forging

H. T2/T3 Heat TreatG. T2/T3 Machining

F. T2/T3 Powder Metal I. T2/T3 Plating

E. T2/T3 Stamp-Form

L.

P. OEM Assembly

Q.

O. Z. MISC

M.

K. T2/T3 Misc. N. T1 Assembly

J. T2/T3Assembly

F. T2/T3 POWDER METAL PROCESS

1 Large Size, High Complexity 1 T2/T3 Powder Metal, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Powder Metal, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Powder Metal, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 2 2 3 3 4 4 5 5

G. T2/T3 MACHINING PROCESS

1 Large Size, High Complexity 1 T2/T3 CNC Milling, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 CNC Milling, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 CNC Milling, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 2 2 3 3 4 4 5 51 Large Size, High Complexity 1 T2/T3 CNC Turning, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 CNC Turning, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 CNC Turning, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 2 2 3 3 4 4 5 5

H. T2/T3 HEAT TREATING PROCESS

1 Large Size, High Complexity 1 T2/T3 Heat Treat, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Heat Treat, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 5

F1.1 Powder Metal, Structural ComponentsF1.2 Powder Metal, Structural & Bearing Components,F1.3 Powder Metal, Structural & Bearing Components,

G1.1 CNC and Rotary & Linear Transfer MachiningG1.2 CNC and Rotary & Linear Transfer MachiningG1.3 CNC and Rotary & Linear Transfer MachiningG2.2 CNC TurningG2.1 CNC TurningG2.3 CNC Turning

H1.1H1.2

Heat Treating,Heat Treating,

File: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.5, Page 3 of 5 
APPENDIX E.5 Mark-up Rate Database Excerpt 

Production Year/Case Study End Item Scrape Average Annual Adjustment Factor (AAF) Selling, General, and Administrative (SG&A), Average Annual AdjustProfit, Average Annual Adjustment Factor (AAF) 

TOP BOTTOM ED&T/R&D, Average Annual Adjustment Factor (AAF) 

End Item 

Scrap,

Active 

Rate

SG&A, 

Active 

Rate

Profit,

Active 

Rate

ED&T/ 

R&D, 

Active 

Rate

End Item 

Scrap 

Rate, 

Baseline

SG&A 

Rate,

 Baseline

Profit 

Rate,

Baseline

ED&T/ 

R&D 

Rate, 

Baseline

End 

Item 

Scrap, 

AAF

SG&A,

AAF

Profit, 

AAF

E

R

2020 2008 2008 2008

Item

Supplier/OEM Classification 

(Based On Manufacturing 

Overhead Categories)

OEM or Supplier 

Classification

Supplier/OEM Size & 

Complexity Description Cat.

A. T2/T3 ThermoPlast.

B. T2/T3 Thermoset

C. T2/T3 Casting 

D. T2/T3 Forging

H. T2/T3 Heat TreatG. T2/T3 Machining

F. T2/T3 Powder Metal I. T2/T3 Plating

E. T2/T3 Stamp-Form

L.

P. OEM Assembly

Q.

O. Z. MISC

M.

K. T2/T3 Misc. N. T1 Assembly

J. T2/T3Assembly

1 Small Size, Low Complexity 1 T2/T3 Heat Treat, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

J. T2/T3 ASSEMBLY PROCESS

1 Large Size, High Complexity 1 T2/T3 Mech. Assembly, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Mech. Assembly, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Mech. Assembly, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 2 2 3 3 4 4 5 51 Large Size, High Complexity 1 T2/T3 Elect. Assembly, LSHC 0.70% 7.00% 8.00% 2.00% 0.70% 7.00% 8.00% 2.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Medium Size, Moderate Complexity 1 T2/T3 Elect. Assembly, MSMC 0.50% 6.50% 6.00% 1.00% 0.50% 6.50% 6.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 51 Small Size, Low Complexity 1 T2/T3 Elect. Assembly, SSLC 0.30% 6.00% 4.00% 0.00% 0.30% 6.00% 4.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

N. T1 Assembly

1 1 T1 System Assembly Complexity 0.70% 7.00% 8.00% 6.00% 0.70% 7.00% 8.00% 6.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 T1 High Assembly Complexity 0.70% 7.00% 8.00% 4.00% 0.70% 7.00% 8.00% 4.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 T1 Moderate Assembly Complexity 0.50% 6.50% 6.00% 2.50% 0.50% 6.50% 6.00% 2.50% 0.00% 0.00% 0.00% 02 23 34 45 51 1 T1 Low Assembly Complexity 0.30% 6.00% 4.00% 1.00% 0.30% 6.00% 4.00% 1.00% 0.00% 0.00% 0.00% 02 23 34 45 5

N1.4 T1 Low Complexity Component SupplierN1.3 T1 Moderate Complexity Component Supplier

J1.2 General Mechanical Assembly

H1.3 Heat Treating,

J1.3 General Mechanical AssemblyJ1.1 General Mechanical AssemblyJ2.1 General Electrical AssemblyJ2.2 General Electrical AssemblyJ2.3 General Electrical Assembly

N1.1 T1 Complete System/System SupplierN1.2 T1 High Complexity Component Supplier

File: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.5, Page 4 of 5 
APPENDIX E.5 Mark-up Rate Database Excerpt 

Production Year/Case Study End Item Scrape Average Annual Adjustment Factor (AAF) Selling, General, and Administrative (SG&A), Average Annual AdjustProfit, Average Annual Adjustment Factor (AAF) 

TOP BOTTOM ED&T/R&D, Average Annual Adjustment Factor (AAF) 

End Item 

Scrap,

Active 

Rate

SG&A, 

Active 

Rate

Profit,

Active 

Rate

ED&T/ 

R&D, 

Active 

Rate

End Item 

Scrap 

Rate, 

Baseline

SG&A 

Rate,

 Baseline

Profit 

Rate,

Baseline

ED&T/ 

R&D 

Rate, 

Baseline

End 

Item 

Scrap, 

AAF

SG&A,

AAF

Profit, 

AAF

E

R

2020 2008 2008 2008

Item

Supplier/OEM Classification 

(Based On Manufacturing 

Overhead Categories)

OEM or Supplier 

Classification

Supplier/OEM Size & 

Complexity Description Cat.

A. T2/T3 ThermoPlast.

B. T2/T3 Thermoset

C. T2/T3 Casting 

D. T2/T3 Forging

H. T2/T3 Heat TreatG. T2/T3 Machining

F. T2/T3 Powder Metal I. T2/T3 Plating

E. T2/T3 Stamp-Form

L.

P. OEM Assembly

Q.

O. Z. MISC

M.

K. T2/T3 Misc. N. T1 Assembly

J. T2/T3Assembly

P. OEM ASSEMBLY

1 1 OEM Body & White Assembly 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 OEM Engine Casting 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 OEM Engine Machining 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 OEM Engine Assembly 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 OEM Vehicle Assembly 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 51 1 OEM Transmission Assembly 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

Z. MISCELLANEOUS

1

Category to be referenced when there is no impact on Mark-up associated with technology change.

1 Not Applicable 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0

2 23 34 45 51 1 T1 Assembly, Mark-up Applied @ Bottom. 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 02 23 34 45 5

P1.4 Engine AssemblyP1.3 Machining Major Engine ComponentsP1.2 Casting Major Engine ComponentsP1.1

Body & White Assembly - OEM, Includes Press Shop, Welding and Painting

P1.5 Vehicle Operations Assembly

Z1.1 Not ApplicableZ1.2 T1 Assembly, Mark-up Captured @ Bottom of quote sheet.

P1.6 Transmission Assembly

File: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13 E.5, Page 5 of 5 
APPENDIX E.6 Packaging Costing Database Excerpt 

"Inches" "mm" "Inches" "mm"

Length 53' 636 16154 570 14478

2. Standard Widths: 96"-102" Width 102" 102 2591 98.5 25023. Standard Heights: 12.5'-13.5' Overall Height 13.5' 162 4115 107.375 2727

Units Length Width

Height

or 

Thickness

Length Width

Height

or 

Thickness

A Primary Packaging Containers and Pallets

Inches 48 45 34 44 41.5 27.5

Other Heights Considered (39'', 42'', 48'', 50'')

mm 1214 1139 860 1113 1050 696 Max Weight 2000lbsInches 48 44 6 48 44 6 Max Weight 2800lbsmm 1214 1113 152 1214 1113 152Inches 21.9 15.2 12.8 19.7 14 11mm 554 385 324 498 354 278Inches 20 12 12 19 11 11mm 506 304 304 481 278 278

B Retunable Internal & Support Dunnage

Inches 48 45 0.25 48 45 0.25mm 1214 1139 6 1214 1139 6Inches 19.7 14 0.10 19.7 14 0.10mm 498 354 2.5 498 354 2.5Inches 44 41.5 NA 44 41.5 NAmm 1113 1050 NA 1113 1050 NAInchesmm

C Expendable Internal Dunnage

Inches 44 41.5 0.12 44 41.5 0.12mm 1113 1050 3 1113 1050 3Inches 44 41.5 NA 44 41.5 NAmm 1113 1050 NA 1113 1050 NA

B3

C3

B4 Seat Belt, Tie-down Straps Estimated cost per pallet for primary packaging option A2 

Dimension Notes: Associated Packaging

E

Used with option A2 primary packaging. 

C2 Cardboard Divider Pads, Generic Assumption 

Used with option A1 primary packaging. 

C1 Cardboard Tier Pads Used with option A1 primary packaging. 

B2 0.10" ABS Vacuum Form Tier Pads Used with option A3 or A4 primary packaging. 

0.10" Corrugated Plastic Dividers, Generic Assumption

Used with option A1 primary packaging. This is an average estimated cost independent of number of cells.

1. Standard Lengths: (28', 32', 36', 40', 42', 43', 45', 48', and 53' )

Exterior 

Dimensions

Interior 

Dimensions

Project

Trailer Size

Selection

Freight Trailer Key Dimensions

A2

Internal dunnage either expendable or returnable.Returnable vacuum formed tier pads.Stacked on base pallet, 6 Totes/Layer, Max 7 LayersStacked on base pallet, 6 Totes/Layer, Max 7 Layers

Standard AIAG Container, 4 Door, Collapsible Side WallsMulti Use Rackable PalletStackable Totes (Flexcon)Stackable Totes (Generic)

Interior Dimensions

A1

1/4" HDPE Vacuum Form Tier Pads

A3A5B1

Exterior Dimensions

Option Packaging Description

A4

Freight Trailer Information Source: www.worldtraderef.com/WTR_site/Truck_Trailers/Guide_to_Truck_Trailers.asp

File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA1-3 E.6, Page 1 of 1 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 1 of 16 

 Note: Following the table is a sample MAQS worksheet identifying the major sections.

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

A SECTION A: MAQS HEADER INFORMATION 

A1 Project Details Enter case study 

information into MAQS 

header. 

CBOM P-VCSM Costs captured in 

Subsystem Cost Model 

Analysis Templates 

(CMAT) are referenced 

by header information 

in the MAQS 

worksheet 

A2 Quote Assumptions 

 Capacity Planning 

Assumptions 

Enter capacity planning 

volume assumptions into 

MAQS header. 

CFT & P-VCSM OEM Benchmark 

Data 

weekly component 

volume provides base 

for all capacity 

planning estimates in 

MAQS worksheet. 

 OEM/T1 Classification Enter Tier 1(T1)/OEM 

classification for mark-up 

factor designation. 

CFT, 

Mark-up 

Database

Supplier 

Benchmark Data 

Mark-up rates are 

automatically loaded 

into MAQS cost 

summation section 

 Packaging Specification Enter, packaging 

specification assumptions 

CFT Packaging 

Database

Defines packaging 

strategy to use when 

developing packaging 

costs. 

 Component Quote 

Level 

Check quote level box in 

header to identify quoting 

level. 

C-BOM, Process 

Mapping

NR Defines quote 

methodology to be 

used in MAQS 

worksheet and how 

costs are to be 

presented in CMAT’s 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 2 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

B SECTION B: MAQS QUOTE SUMMARY 

B1 General Component Information 

 Reference Number Enter alpha numeric 

reference number for each 

process and/or part added 

to the MAQS. 

Defaults set in 

MAQS 

NR Reference numbers are 

a quick method of 

reviewing multiple 

processes performed on 

same part. 

 Part Description Enter, part 

name/description. 

CBOM, 

Process 

Mapping

FEV or Munro 

historical naming 

conventions 

Part description create 

main field for 

identifying parts within 

Bill of Materials 

 Part Number Enter, part number CBOM, 

Process 

Mapping

FEV historical 

numbering 

conventions 

Part Number creates 

main field for 

identifying processing 

level of a part within 

Bill of Materials 

 Quantity per Assembly Enter quantity of a part 

within the 

component/assembly. 

CBOM, 

Process 

Mapping

Teardown process, 

service manuals, 

etc. 

The quantity value 

enter is used through 

out the MAQS 

worksheet. More 

details are provided 

below. 

 

B2 General Manufacturing Information 

 Primary Process 

Description 

Enter summary 

description of process 

Process 

Mapping

NR Reference Only 

 OEM/Supplier 

Classification 

(When referencing all 

quote levels with 

exception of Purchase 

Part – Commodity) 

Enter OEM/Supplier 

Classification for identified 

process using Mark-up 

Database nomenclature. 

MAQS Burden 

Classification 

Mark-up Database

CFT makes 

assessment on 

what type of 

manufacturing 

facility makes the 

part: T1 versus 

OEM, T1 versus 

T2/T3 

Automatically loads 

mark-up rate from 

database into mark-up 

cost section of MAQS 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 3 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

 OEM/Supplier 

Classification 

(When referencing 

Purchase Part – 

Commodity quote level) 

Enter predefined alpha 

numeric characters to 

direct commodity based 

purchase part costs to 

different areas of the 

MAQS worksheet. 

MAQS Quote 

Summary 

section contains 

legend of 

applicable 

values. 

“S” = purchase component, cost binned to 

T1/OEM material cost. 

“Alpha Numeric Characters” matching 

reference number e.g., B2A, places the 

purchase cost as T2/T3 material cost subject 

to additional mark-up. 

“SAC” = Purchase component cost is only 

included in the MAQS worksheet to have a 

Mark-up factor accounted for by the T1 (or 

OEM if applicable). The actual component 

cost is kept in a separate MAQS worksheet to 

keep the cost resolution. 

 Material Specification Enter material type 

identified in process using 

Material Database 

nomenclature. 

CBOM/ Process 

Mapping

Material Database Automatically loads 

material cost from 

database into 

manufacturing rates 

section of MAQS 

 Labor Classification Enter Labor type used in 

process using Labor 

Database nomenclature. 

Process 

Mapping

Labor Database Automatically loads 

labor rate from 

database into 

manufacturing rates 

section of MAQS 

 Burden Classification Enter Burden type used in 

process using Burden 

Database nomenclature. 

Process 

Mapping & 

MAQS 

Manufacturing 

Assumptions 

Manufacturing 

Overhead/Burden 

Database

Automatically loads 

burden rate from 

database into 

manufacturing rates 

section of MAQS 

B3 Manufacturing Rates 

 Finished Piece/Hour The rate parts are produced 

at for the defined process. 

Automatically populated 

from Manufacturing 

Assumption section of 

MAQS 

Process 

Mapping and 

Manufacturing 

Assumptions 

section of 

MAQS 

NR Variable used in the 

calculation of labor and 

burden costs. 

 Number of Operators Number of operators 

required for the defined 

process. Automatically

populated from the 

Manufacturing Assumption 

Section of the MAQS 

MAQS 

Manufacturing 

Assumption 

section 

NR Variable used in the 

calculation of labor 

costs. 

 Number of Lines Number of pieces of 

similar equipment/lines 

required for the defined 

process to meet rate. 

Automatically populated 

from the Mfg’ing 

Assumption. Section of the 

MAQS. 

MAQS 

Manufacturing 

Assumption 

section 

NR Variable used in the 

calculation of the 

Applied Burden rate. 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 4 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

 Parallel Processing 

Multiplier 

Number of pieces of 

parallel processing 

equipment required for the 

defined process to meet 

rate. Automatically

populated from the 

Manufacturing Assumption 

section of the MAQS. 

MAQS 

Manufacturing 

Assumption 

section 

NR Variable used in the 

calculation of Applied 

Burden rate. 

 Material Usage “lbs” Enter total amount of 

material used to process 

single part per defined 

process. 

Process 

Mapping

NR Variable used in the 

calculation of material 

costs. 

 Material Cost $/lb Automatically uploaded 

from Material Database 

Material 

Database

Material 

Specification 

Variable used in the 

calculation of material 

costs. 

 Labor Rate $/Hr Automatically uploaded 

from Labor Database 

Labor Database Labor 

Classification 

Variable used in the 

calculation of labor 

costs. 

 Burden Rate $/Hr Automatically uploaded 

from Burden Database 

Burden Database Burden 

Classification 

Variable used in the 

calculation of Applied 

Burden Rate. 

 Applied Burden Rate 

$/Hour 

Total burden rate 

considering multiple piece 

of equipment performing 

the same task and/or using 

equipment/lines with 

parallel processing 

capabilities. 

Automatically calculated in 

Quote Summary Section of 

MAQS 

Number of Lines 

x Parallel 

Processing 

Multiplier x 

Burden Rate = 

Applied Burden 

Rate. 

Quote Summary 

section of MAQS 

Variable used in the 

calculation of burden 

costs. 

B4 Manufacturing Costs 

 Material Costs “$” Material cost for defined 

process. Automatically

calculated in Quote 

Summary section of 

MAQS 

Material Usage 

“lbs” x Material 

Cost “$/lb” 

Pull data from 

Manufacturing 

Rates section of 

MAQS 

Material contribution 

to TMC “Total 1” for 

the defined process. 

 Labor/Part “$” Labor cost for defined 

process. Automatically

calculated in Quote 

Summary section of 

MAQS 

=(Labor Rate 

“$/Hr” x 

Number of 

Operators)/ 

Finished 

Piece/Hour 

Pull data from 

Manufacturing 

Rates section of 

MAQS 

Labor contribution to 

TMC “Total 1” for the 

defined process. 

 Burden/Part “$” Burden cost for defined 

process. Automatically

calculated in Quote 

Summary sec. of MAQS 

=(Applied 

Burden Rate 

“$/Hr”)/ 

Finished 

Piece/Hour 

Pull data from 

Manufacturing 

Rates section of 

MAQS 

Burden contribution to 

TMC “Total 1” for the 

defined process. 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 5 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

 Total 1 = Material + 

Labor + Burden “$” 

Total 1 = Total 

Manufacturing Cost for the 

defined value add process. 

Automatically calculated in 

Quote Summary section of 

MAQS 

= Material Cost 

“$” + Labor/Part 

“$” + Burden/ 

Part “$” 

Pull data from 

Manufacturing 

Cost section of 

MAQS 

Variable used to 

calculate Mark-up 

Contribution, “Total 2” 

and “Total 3” 

(additional details 

below) 

 

B5 Mark-up Costs 

 End Item Scrap Rate 

“%” 

End Item Scrap Rate for 

defined process. 

Automatically uploaded 

from Mark-up Database 

Mark-up 

Database

OEM Supplier 

Classification 

Used in calculation of 

End Item Scrap costs 

for defined process. 

 SG&A Rate “%” SG&A rate for defined 

process. 

Automatically uploaded 

from Mark-up Database 

Mark-up 

Database

OEM Supplier 

Classification 

Used in calculation of 

SG&A costs for 

defined process. 

 Profit Rate “%” Profit rate for defined 

process. 

Automatically uploaded 

from Mark-up Database 

Mark-up 

Database

OEM Supplier 

Classification 

Used in calculation of 

profit costs for defined 

process. 

 ED&T Rate “%” ED&T rate for defined 

process. 

Automatically uploaded 

from Mark-up Database 

Mark-up 

Database

OEM Supplier 

Classification 

Used in calculation of 

ED&T costs for 

defined process. 

 Total Mark-up Rate 

“%” 

Total Mark-up rate for 

defined process. 

 Automatically calculated 

in Quote Summary Section 

of MAQS 

= End Item 

Scrap + SG&A 

+ Profit +ED&T 

“%” 

Calculated from 

data in Mark-up 

Cost section of 

MAQS 

Used in calculation of 

Total Mark-up Costs 

for defined process. 

 Total Mark-up Costs 

“$” 

Total Mark-up Cost for 

defined process. 

Automatically calculated in 

Quote Summary Section of 

MAQS 

=Total Mark-up 

Rate “%” x 

Total 1 “$” 

Calculated from 

data in Mark-up 

Costs and 

Manufacturing 

Costs Sections of 

MAQS 

Used in calculation of 

Total 2 (See below for 

additional details) 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 6 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

B6 Total Costs 

 Total 2 = Total 1 + 

Total Mark-up 

Total 2 is different than 

Total 1 only for 

components processed by 

T2/T3 suppliers because of 

the added mark-up. 

Automatically calculated in 

Quote Summary Section of 

MAQS 

=Total 1 $ + 

Total Mark-up 

Cost $ 

Calculated from 

data in Mark-up 

Costs and 

Manufacturing 

Costs sections of 

MAQS 

Used in calculation of 

Total 3 (See below for 

additional details) 

 Total 3 = Total 2 * 

QTY/Assembly 

Total 3 accounts for cases 

where multiple pieces are 

required in the assembly. 

Automatically calculated in 

Quote Summary Section of 

MAQS 

Total 3 = Total 2 

$ * QTY/ 

Assembly 

Calculated from 

data in Total Costs 

& General 

Component 

Information 

sections of MAQS 

The “Total 3” costs are 

added up from all four 

quote levels (T1 or 

OEM, Purchase-High 

Impact, Purchase-Low 

Impact and PurchaseCommodity) to arrive 

at the component/ 

assembly Total 

Manufacturing Cost. 

B7 Tooling and Investment 

 Tooling Assumptions Enter those tooling costs 

and assumptions which 

cannot be excluded as a 

result of the technology 

differences between the 

base and new technology 

configurations. 

CFT NR Tooling is totaled for 

the base and new 

technology 

configurations and a 

differential calculated 

in the Subsystem and 

System Cost Model 

Summary Templates. 

 Investment 

Assumptions 

Enter Unique investment 

costs and assumptions 

which may drive burden 

rate changes. 

CFT NR Unique Investment 

cases and costs are 

captured for potential 

development of new 

burden rates. 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 7 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) 

FOR TASK 

OUTPUT SOURCE(S) 

FOR TASK 

C SECTION C: MAQS BREAKOUT CALCULATOR- REFERENCE ONLY “Costs 

broken out into categories with quantity per assembly taken into account” 

C1 Manufacturing Costs 

Manufacturing Cost 

(QTY) 

>Material 

>Labor 

>Burden 

>TMC 

Takes into account quantity 

(qty) of components per 

assembly to calculate Total 

Material, Labor and 

Burden and TMC per 

defined process. 

Automatically calculated in 

Breakout Calculator 

section of MAQS 

Total Material = 

Material Cost x 

QTY. 

Total Labor = 

Labor Cost x 

QTY. 

Etc.... 

Calculated from 

the Manufacturing 

Cost and General 

Component 

Information 

sections of MAQS 

The costs for each 

manufacturing cost 

element (material, 

labor, etc) are added up 

from all four quote 

levels (T1 or OEM, 

Purchase-High Impact, 

Purchase-Low Impact, 

and PurchaseCommodity) to arrive 

at the total cost 

contribution, for each 

element, for the 

component/assembly. 

C2 Mark-up Costs 

 Mark-up Costs (QTY) 

>End Item Scrap 

> SG&A 

>Profit 

>ED&T 

>Total Mark-up Cost 

Takes into account qty. of 

components per assembly 

and sets mark-up rates to 

calculate Total Mark-up 

Costs for each mark-up 

category per the defined 

process. 

Automatically calculated in 

Breakout Calculator 

section of MAQS 

Total End Item 

Scrap = QTY. x 

Total 1 x End 

Item Scrap rate. 

Total SG&A = 

QTY. x Total 1 

x SG&A Rate 

Etc..... 

Calculated from 

the General 

Component 

Information, 

Manufacturing 

Cost and Mark-up 

Cost Sections of 

MAQS 

The costs for each 

mark-up cost element 

(scrap, SG@A etc) are 

added up from all four 

quote levels (T1 or 

OEM, Purchase-High 

Impact, Purchase-Low 

Impact, and PurchaseCommodity) to arrive 

at the total cost 

contribution, for each 

mark-up element, for 

the component/ 

assembly. 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 8 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

D SECTION D: MANUFACTURING ASSUMPIONS 

D1 Process Information 

 Process and Equipment 

Assumptions 

Enter, define mass 

production manufacturing 

methodology based off 

serial process mapping 

Process 

Mapping and 

CFT 

Historical industry 

data and expertise 

Process and equipment 

assumptions provide 

support information 

for “Project Process 

Requirement” 

(Manufacturing 

Assumption Section of 

MAQS) 

 Tooling, Fixturing and 

Gauge Assumptions 

Enter, define tooling 

impact associated with 

technology upgrade 

features. 

Process 

Mapping and

CFT 

Historical industry 

data and expertise 

Tooling, fixture and 

gauge assumptions 

provide support 

information for “Tool 

Assumption Costs” 

(Quote Summary 

Section of MAQS) 

D2 Process Operation Pattern 

 Day/Week Enter, default is 5, 

assumption is everyone on 

average operates 5 

days/week to capitalize on 

investment. 

MAQS 

Manufacturing 

Assumption 

section 

NR Variable used in 

calculation of available 

hours/week for 

manufacturing. 

 Shifts/Day Enter, default is 2, 

assumption is everyone on 

average operates 2 

shifts/day to capitalize on 

investment. 

MAQS 

Manufacturing 

Assumption 

section 

NR Variable used in 

calculation of available 

hours/week for 

manufacturing. 

 Hrs./Shift Enter, default is 10, 

Selected 10 as default 

supporting heavy 

automation, complex setups and long change-over 

times for majority of 

components. 

MAQS 

Manufacturing 

Assumption 

section 

NR Variable used in 

calculation of available 

hours/week for 

manufacturing. 

 Hrs/Wk. Automatically calculated, 

average available hours per 

week for manufacturing. 

=Day/week x 

Shifts/Day x 

Hrs/Shift 

Manufacturing 

Assumption 

section of MAQS 

Variable used in 

calculation of 

Pieces/Hour. 

 Wks./Yr. Enter, default is 47, 

assumption is everyone on 

average operates 47 

week/year to capitalize on 

investment. 

MAQS 

Manufacturing 

Assumption 

section 

NR Variable used in 

calculation of available 

Hours/Yr for 

manufacturing. 

 Hrs./Yr. Automatically calculated, 

average available hours per 

year for manufacturing 

=Hrs/Wk x 

Wks/Yr. 

Manufacturing 

Assumption 

section of MAQS 

NR 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 9 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

D3 Minimum Calculated Cycle Times 

 Pcs./Hr. (100% Eff.) Automatically calculated, 

number of piece required 

per hour from the 

manufacturer to support the 

OEM facility (on weekly 

basis) assuming 100% 

efficiency 

=(Weekly 

ComponentAssembly 

Volume x QTY 

per Assembly) / 

Hrs./Week 

Manufacturing 

assumption data 

from MAQS Header 

Sec., General 

Component 

Information from 

MAQS Quote 

Summary sec., and 

Hrs/Week 

information from 

Manufacturing 

Assumption sec. of 

MAQS 

Variable used in 

calculation or Pcs./Hr. 

@ Stated Efficiency 

 Cycle Time/Operation 

“Sec.” 

Automatically calculated, 

tack time per part in 

seconds @ 100% 

efficiency 

=(Pcs./Hr.)/ 

3600 Seconds 

Manufacturing 

Assumption 

section of MAQS 

Reference only 

 Efficiency % (Stated 

Efficiency) 

Enter, default 85%, 

assumption with breaks, 

downtime, etc., average 

manufacturing time 

available would be 8.5 

hours out of 10. 

CFT Historical industry 

data and expertise 

Variable used in 

calculation of Pcs./Hr 

at stated efficiency. 

 Pcs./Hr. @ Stated 

Efficiency 

Automatically calculated, 

number of piece required 

per hour from the 

manufacturer to support the 

OEM facility (on weekly 

basis) assuming efficiency 

“X”

= Pcs./Hr. 

(100% Eff.)/ 

Efficiency 

Manufacturing 

assumption data 

from MAQS Header 

Sec., General 

Component 

Information from 

MAQS Quote 

Summary sec., and 

Hrs/Week 

information from 

Manufacturing 

Assumption sec. of 

MAQS

Value establishes 

specification to ensure 

defined mass 

production process can 

meet capacity. 

“Resulting Pcs./Hr. ≥

“Pcs./Hr. @ Stated 

Efficiency” 

 Cycle Time/Operation 

@ State Efficiency 

“Sec” 

Automatically calculated, 

tack time per part in 

seconds @ stated 

efficiency 

(Pcs./Hr. @ 

State 

Efficiency)/ 

3600 Seconds 

Manufacturing 

Assumption 

section of MAQS 

Reference Only 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 10 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

D4 Project Process Requirements 

 Lean Design 

Calculation for 

Complete Process Time 

"Sec." 

Enter, total serial 

processing time for a 

defined process from 

Process Map. 

Process 

Mapping 

NR Total serial process time is 

referenced to mass 

production assumption 

calculations e.g., 

(Piece/Cycle/ Machine) x 

(Tack Time /Machine/ 

Cycle) x (Parallel 

Processing Multiplier) x 

(Number of Equipment/ 

Machine Required). 

Pending situation mass 

production assumption 

calculation ≤ total serial 

process time. 

 Parallel 

Operations/Machine or 

Stations/Line 

Enter, based on process 

and equipment 

assumptions is the total 

number of operations 

performed for a defined 

process. 

Process and 

Equipment 

Assumptions 

MAQS 

Manufacturing 

Assumption 

section 

Reference for 

establishing parallel 

processing 

requirements and 

number of equivalent 

lines/equipment. 

 Piece/Cycle/Machine Enter, accounts for 

equipment/processes where 

multiple parts can be 

produced at the same time 

(e.g., multiple cavity 

injection mold) 

Process 

Mapping and

Process and 

Equipment 

Assumptions 

MAQS 

Manufacturing 

Assumption 

section 

Variable used in 

calculation of 

“Resulting Piece/Hour” 

 Tack 

Time/Machine/Cycle 

"Seconds" 

Enter, based on Process 

and Equipment 

Assumptions is the time it 

takes for a given piece of 

equipment from start to 

finish to complete it’s 

process cycle. 

Process 

Mapping and

Process and 

Equipment 

Assumptions 

MAQS 

Manufacturing 

Assumption 

section 

Variable used in 

calculation of 

“Resulting Piece/Hour” 

 Multiplier, If Required 

for Parallel Processing 

(1=Nothing) 

Enter, based on process 

and equipments 

assumptions is the 

assignment of a burden 

multiplier to account for 

equipment with parallel 

processing capabilities. 

(e.g., 7 Part Spindle 

Turning CNC Machine 

versus a single part spindle 

turning machine) 

Process and 

Equipment 

Assumptions 

MAQS 

Manufacturing 

Assumption 

section 

Populates “Parallel 

Processing Multiplier” 

in the Quote Summary 

section of the MAQS 

for Applied Burden 

Rate calculation. 

 Number of Equivalent 

Machines Required 

Enter, based on required 

pieces/hr. @ stated 

efficiency, is the number of 

pieces of equipment 

required to meet capacity 

rates. 

Required 

“Pcs./Hr. @ 

Stated 

Efficiency” and 

“Resulting 

Pieces /Hour” 

from defined 

process and 

equipment 

assumptions 

MAQS 

Manufacturing 

Assumption 

section 

Populates “Number of 

Lines” in the Quote 

Summary section of the 

MAQS for Applied 

Burden Rate 

calculation. 

Variable used in 

calculation of 

“Resulting Piece/Hour” 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 11 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

 Resulting Pieces/Hour Automatically calculated, 

defines the pieces per hour 

which can be manufactured 

under the defined mass 

production process and 

equipment assumptions. 

= {3600 

seconds/ (Tack 

Time/Machine/C

ycle)} * 

{(Pieces/ 

Machine/Cycle) 

* ( Number of 

Equivalent 

Machines 

Required)} 

MAQS 

Manufacturing 

Assumption 

section 

Populates “Finished 

Pieces/Hour” in the 

Quote Summary 

section of the MAQS 

which is then used in 

the calculation of labor 

and burden costs. 

 

 Resulting Cycle Time/ 

Part "Sec” 

Automatically calculated, 

defines the average tack 

time per part based on 

resulting pieces/hour. 

=3600 Seconds/ 

( Resulting 

Pieces/Hour) 

MAQS 

Manufacturing 

Assumption 

section 

Checked with respect 

to “Cycle 

Time/Operation @ 

Stated Efficiency “Sec” 

to ensure 

manufacturing process 

and equipment 

assumptions can meet 

capacity requirements. 

 Total Number of Direct 

Operators 

Enter, the number of direct 

laborers required to support 

Process and equipment 

assumptions 

Process and 

Equipment 

Assumptions 

MAQS 

Manufacturing 

Assumption 

section 

Populates “Number of 

Operators” in the 

Quote Summary 

section of the MAQS 

which is then used in 

the calculation of labor 

Costs. 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 12 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

E SECTION E: PACKAGING CALCULATIONS 

E1 Packaging Calculation 

 Package Calculation 

Data Entry Box 

Enter, the selected 

packaging configuration, 

part size and expected pack 

density. 

Packaging 

Database, Part 

Measurements 

Information 

MAQS Header - 

Packaging 

Assumptions 

Expected pack density 

variables feed “Number 

of Parts per 

Pallet/Rack” 

calculation. 

E2 Rack/Pallet Investment Amortization 

 Supplier, Customer and 

In-transit Inventory 

Requirements (Parts) 

Automatically calculated, 

defines the total inventory 

required to support the 

“Supplier, Customer and 

In-transit Inventory 

Requirements” 

= Weekly 

Component 

Volume X 

“Supplier, 

Customer and 

In-transit 

inventory 

requirements” 

MAQS Header and 

Packaging section. 

Variable used to 

determine total number 

of pallets/racks 

required. 

 Supplier, Customer and 

In-transit Inventory 

Requirements (Weeks) 

Enter, default 6 weeks, 

number of weeks of 

packaging required to 

cover plant stock turn-over, 

transit times, container 

cleaning, etc 

CFT NR Variable used to 

calculate “Supplier, 

Customer and In-transit 

Inventory 

Requirements”. 

 Number of Parts per 

Pallet/ Rack 

Enter, for base ballet 

assumptions (48”x45”) 

how many parts can be 

loaded onto pallet 

maintaining height 

requirements. 

Packaging 

Database,

Package 

Calculation 

Entry Box 

NR Variable used to 

determine total number 

of pallets/racks 

required. 

 Total Number of 

Pallets/ Racks Required 

Automatically calculated 

defines how many 

complete pallets/racks are 

required to support 

supplier, customer and intransit inventory 

requirements 

= (Supplier, 

Customer and 

In-transit 

Inventory 

Requirements 

(Parts))/ (# of 

Parts per Pallet/ 

Rack) 

MAQS Package 

Calculation section 

Variable used to 

determine Total 

Packaging Costs. 

 Cost per Pallet /Rack Enter, cost of one 

complete pallet/rack set. 

Packaging 

Database,

Package 

Calculation 

Entry Box 

MAQS Package 

Calculation section 

Variable used to 

determine Total 

Packaging Costs 

 Interest Rate Enter, default 5%, interest 

rate to cover lost invest. 

opportunity w. packaging 

hardware purchase. 

CFT NR Variable used in 

calculation of 

Returnable 

“Cost/Piece” 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 13 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

 Number of Service 

Months 

Enter, default 60 months, 

expected service life of 

packaging before it needs 

to be replaced. 

CFT NR Variable used in 

calculation of 

Returnable “Package 

Cost/Piece” 

 Total # of Pieces/ 

Amortization Period 

Automatically calculated, 

defines the total number of 

parts, during the defined 

service life, which will be 

used to amortize the 

packaging costs. 

= Weekly 

Component 

Volume X 

Number of 

Service Months 

X Average 

Weeks/Month 

NR Variable used in 

calculation of 

Returnable 

“Cost/Piece” 

 Lump Sum Payment 

(%) 

Enter, default 0%, any 

upfront customer payments 

towards packaging, 

CFT NR Variable used in 

calculation of 

Returnable “Package 

Cost/Piece” 

 Total Amount Automatically calculated, 

defines the total packaging 

cost for the assumed 

volumes, transit times, 

inventory hold and service 

life, etc. 

= Total Number 

of Pallets/ Racks 

Required X Cost 

per Pallet /Rack 

MAQS Package 

Calculation 

Section 

Variable used in 

calculation of 

Returnable 

“Cost/Piece” 

 Cost/Piece (Returnable) Automatically calculated, 

defines the additional cost 

per part required to cover 

the returnable packaging 

expenditure. 

Calculated using 

standard 

amortization 

formula. 

MAQS Package 

Calculation section 

Cost/Piece is added to 

any contribution from 

expendable packaging, 

if applicable, to obtain 

the Packaging Cost 

Total / Part 

 

E3 Expendable Packing in Piece Cost 

 Tier Pad Piece Price, 

Divider Pad Piece Price, 

Other #1,2,3 Piece 

Price, etc 

Enter, from Packaging 

database enter unit cost of 

identified expendable 

packing. 

Packaging 

Database, 

Package 

Calculation 

Entry Box 

MAQS Package 

Calculation section 

Variable used in 

calculation of 

Expendable 

“Cost/Piece” 

 Tier Pads per 

Pallet/Rack, Divider 

Pads per Pallet/Rack, 

etc 

Enter, from Package 

Calculation Data Entry 

Box, enter quantity of 

identified expendable 

packaging required per 

pallet. 

 Package 

Calculation 

Entry Box 

MAQS Package 

Calculation section 

Variable used in 

calculation of 

Expendable 

“Cost/Piece” 

 Cost/piece 

(Expendable) 

Automatically calculated, 

defines the additional cost 

per part required to cover 

the expendable packaging 

expenditure. 

=(Total 

Expendable 

Packaging 

Expense for 

Pallet) /(Number 

of Parts/Pallet) 

MAQS Package 

Calculation 

Section 

Cost/Piece is added to 

any contribution from 

returnable packaging, 

to obtain the 

Packaging Cost Total / 

Part 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 14 of 16 

MAQS WORKSHEET SECTIONS TASK DESCRIPTION 

INPUT 

SOURCE(S) 

FOR TASK 

REFERENCE 

SOURCE(S) FOR 

TASK 

OUTPUT 

SOURCE(S) FOR 

TASK 

F SECTION 6: UNIT COST SUMMARY 

 

 T1 or OEM Total 

Manufacturing Costs 

(Includes TMC + T2/T3 

Mark-up) 

Automatically calculated, 

presents the Total 

Manufacturing Cost of the 

components including all 

Tier 2/Tier 3 mark-up 

broken out into the 7 cost 

elements. 

MAQS 

Worksheet 

Calculations 

NR Values are used to 

calculate Base Cost 

Impact to Vehicle. 

 T1 or OEM Mark-up 

Rates 

Rates Automatically

loaded when the OEM/T1 

Classification is recoded in 

the header. 

Mark-up 

Database, 

MAQS Worksheet 

Header 

Rates are used to 

calculate Tier 1 (or 

OEM if applicable) 

mark-up costs. 

 (SAC) and T1 or OEM 

Mark-up Values/Costs 

Automatically calculated, 

T1 (or OEM if applicable) 

mark-up costs. 

Note: If there are any 

Purchase Parts – 

Commodity based, 

classified as “SAC’s”, the 

values are subtracted out in 

this area after T1 mark-up 

costs are calculated. 

=(“T1 or OEM 

TMC”) x (“T1 

or OEM Markup Rates”) 

NR T1 (or OEM if 

applicable ) mark-up 

costs are added to TMC 

to obtain Base Cost 

Impact to Vehicle 

 Base Cost Impact to 

Vehicle (Includes TMC 

+ Tier 2/3 Mark-up and 

Tier 1 Mark-up) 

Automatically calculates 

the total base cost for the 

component/assembly 

broken out into the 7 cost 

elements. 

Note: In addition, tooling 

and investment impact (if 

applicable) are summed up 

within this section. 

= (“T1 or OEM 

TMC”) + 

(“(SAC) and T1 

or OEM Markup Values/ 

Costs”) 

NR Total is added to 

Packaging Cost to 

obtain the Net Cost 

Impact to Vehicle. 

Note these values are 

also carried into the 

Subsystem Cost Model 

Analysis Templates 

 Net Cost Impact to 

Vehicle 

Automatically calculated, 

Final Unit Cost Impact to 

Vehicle 

= Base Cost 

Impact to 

Vehicle + 

Packaging 

NR FINAL UNIT COST 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 15 of 16 
APPENDIX F.1 MAQS Worksheet Task Reference Guide 

EPA Contract: EP-C-07-069 WA1-3 F.1, Page 16 of 16 
APPENDIX G.1 

MAQS Worksheets (Worksheet Sections A,B,E and F)

Case Study #0101

Appendix G.1

Printed:12/9/2009

$0.00

Crank Drive Subsystem Appendix G.1 - 03, Pages 1-7 $0.00

Counter Balance Subsystem Appendix G.1 - 04, Pages 1-4 ($35.95)

Cylinder Block Subsystem Appendix G.1 - 05, Pages 1-8 $0.44

Cylinder Head Subsystem Appendix G.1 - 06, Pages 1-8 $16.55

Valve Train Subsystem Appendix G.1 - 07, Pages 1-4 $10.06

Timing Drive Subsystem Appendix G.1 - 08, Pages 1-2 $1.60

Accessory Drive Subsystem Not Applicable $0.00

Intake Subsystem Appendix G.1 - 10, Pages 1-2 ($12.73)

Fuel Induction Subsystem Appendix G.1 - 11, Pages 1-12 $107.32

Exhaust Subsystem Appendix G.1 - 12, Pages 1-6 $37.77

Lubrication (Oil Pans/Sumps) Subsystem Appendix G.1 - 13, Pages 1-11 $34.46

Cooling Subsystem Appendix G.1 - 14, Pages 1-9 $41.56

Induction Air Charging Subsystem Appendix G.1 - 15, Pages 1-16 $258.89

Exhaust Gas Re-Circulations Subsystem Not Applicable $0.00

Breather Subsystem Appendix G.1 - 17, Pages 1-2 $4.17

Appendix G.1 - 60, Pages 1-5 $56.61

Appendix G.1 - 70, Pages 1-4 $16.95

$537.70

MAQS Worksheets 

Location within Appendix 

G.1

Not Applicable

Total Unit Cost =>

Net Incremental 

Component/Assembly Cost 

Impact to OEM

Engine Subsystems

Engine Management, Engine Electronic and 

Electrical Subsystem

Accessory (e.g. Starter Motor, Power Steering 

Pump, Air Conditioning Compressor) Subsystem

Engine Frames, Mountings & Brackets Subsystem

File:Cost Model Analysis Template 120809.xls

EPA Contract:EP-C-07-069 WA1-3 G.1, Page 1 of 1
Appendix G.1 - Subsystem 03

Crank Drive Subsystem

 Case Study #0101

MAQS Worksheets

File:Crank Drives 03, 032509.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-03, 1 of 7
Crankshaft 0301 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Met

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Shaft - Crank Part Number: 0301-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

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

Shaft - Crank (Mini Cooper) 0301-N0101-01 1

Considered for Weight Delta 

Only, Assume Fabrication and Machining times a wash between Mini and Chrysler Crankshaft

OEM MA-Steel-MnVS, Bar Not Applicable Not Applicable 116 0 25.28 $0.73 $0.00 $0.00 $18.45 $0.00 $0.00 $18.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $18.45 $1

Shaft - Crank ( Chrysler Gema) 0301-B0101-01 1 "See Note Above" OEM MA-Steel-MnVS, Bar Not Applicable Not Applicable 116 0 -39.81 $0.73 $0.00 $0.00 -$29.06 $0.00 $0.00 -$29.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$29.06 -$

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purch

Net, 

0 $0.00 $0.00 $0.00 $

0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $

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

T1 or OEM Total Manufacturing Cost: -$10.61 $0.00 $0.00 -$10.61 $0.00 $0.00 $0.00 $0.00 $0.00 -$

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.07 -$0.74 -$0.85 $0.00 -$1.67

Base Cost Impact to Vehicle: -$10.61 $0.00 $0.00 -$10.61 -$0.07 -$0.74 -$0.85 $0.00 -$1.67 -$

Packaging Cost: $

Net Cost Impact to Vehicle: -$

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer and 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and Intransit Inventory 

Requirements 

(Parts)

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

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

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COS

10

9,574

47

450,000

1

450,000

PACKAGIAssume N

"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.

3

1

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 2 of 7
Con.Rod0303 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Rod Subassembly - Connecting Part Number: 0303-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2  Qty per Assy

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

1A Rod Subassembly - Connecting 0303-N0101-01-01 1

Weight Cost Differential Only, Fabrication and Machining are equivalent between Mini & Chrysler Con. Rods.Mini-Cooper RodL/R = 138.5/(85.9/2) = 3.22

S MA-Steel-C70S6, Bar Not Applicable Not Applicable 450 0 0.964 $0.70 $0.00 $0.00 $0.67 $0.00 $0.00 $0.67 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.67 

1B Rod Subassembly - Connecting 0303-N0101-01 1 Install Bushing & Size S Not Applicable General Assembly Mech. Assembly, MC 450 0 0.000 $0.00 $35.51 $125.19 $0.00 $0.00 $0.28 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 2A Rod Subassembly - Connecting 0303-B0101-01&02 1 Chrysler GEMA Rod Weight MA-Steel-C70S6, Bar Not Applicable Not Applicable 450 0 -0.979 $0.70 $0.00 $0.00 -$0.69 $0.00 $0.00 -$0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.69 -2B Rod Subassembly - Connecting 0303-B0101-01&02-M 1

Additional Material Required to Equalize L/R RatioGEMA Prod. L/R = 2.96, R = 97/2 = 48.5 & L =143.75mmAssuming Mini L/R (3.22).Hold stroke constant L=3.22*48.5= 156.17mmTherefore rod length would increase by 12.42mm

MA-Steel-C70S6, Bar Not Applicable Not Applicable 450 0 -0.032 $0.70 $0.00 $0.00 -$0.02 $0.00 $0.00 -$0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.02 -

Purchase Part - Commodity ( Value taken from Purchase Part Database) Supplier Account Cost Purchase Price/ Unit Purchase Price Net, PIA Purc

Net, 

Bushing - Connecting Rod 0303-N0101-02 1 Aluminum Bronze S $0.00 $0.33 $0.00 

0 (Blank 40x30x0.5 mmm) $0.00 $0.00 $0.00 0 Mean ρ = 0.270 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 

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

T1 or OEM Total Manufacturing Cost: $0.30 $0.00 $0.28 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.04 $0.03 $0.01 $0.09

Base Cost Impact to Vehicle: $0.30 $0.00 $0.28 $0.58 $0.00 $0.04 $0.03 $0.01 $0.09 

Packaging Cost: 

Net Cost Impact to Vehicle: 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL CO

10

38,298

47

450,000

4

1,800,000

"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.

3

1

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 3 of 7
Con.Rod0303 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Rod Subassembly - Connecting Part Number: 0303-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2  Qty per Assy

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL CO

10

38,298

47

450,000

4

1,800,000

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer and 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and 

In-transit 

Inventory 

Requirements 

(Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 18,000,000 60 5.00% $0 229787 1 6 229787

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 $1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGNo Chang

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 4 of 7
Piston0304 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Piston - Engine, Machined Part Number: 0304-N0101-01 Weekly Component Volume: P

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) P

R

(D

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

1A Piston - Engine, Cast (Mini Cooper) 0304-N0101-01-01 1

Consider weight, material and scrap (+5%) differences in cast hypereutectic material.

T2/T3 Internal Supplier Aluminum-B390, Cast Mold/Cast/Sinter Operator Diecast, LMC 517 3 3 1 0.651 $1.20 $43.52 $100.05 $300.15 $0.78 $0.25 $0.58 $1.61 5.00% 0.00% 0.

1B Piston - Engine, Machined (Mini Cooper) 0304-N0101-01-01 1 T6 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 442 2 4 1 0.000 $0.00 $46.52 $100.00 $400.00 $0.00 $0.21 $0.90 $1.12 0.00% 0.00% 0.

1C Piston - Engine, Machined (Mini Cooper) 0304-N0101-01 1 Machining (5% Premium on Time Accounted for in rate) T2/T3 Internal Supplier Not Applicable CNC Operator Rot./Lin. Trans. Machining Line, TP, PREM. 480 1 2 1.05 0.000 $0.00 $35.70 $260.00 $546.00 $0.00 $0.07 $1.14 $1.21 0.00% 0.00% 0.

2A Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-01 1

Consider weight and material differences only as cost factor in primary fabrication process.

T2/T3 Internal Supplier Aluminum-384, Cast Mold/Cast/Sinter Operator Diecast, LMC -514 3 3 1 -0.764 $1.14 $43.52 $100.05 $300.15 -$0.87 -$0.25 -$0.58 -$1.71 0.00% 0.00% 0.

2B Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-01 1 T5 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, LMC -420 1 2 1 0.000 $0.00 $46.52 $50.00 $100.00 $0.00 -$0.11 -$0.24 -$0.35 0.00% 0.00% 0.

2C Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-01 1 Machining T2/T3 Internal Supplier Not Applicable CNC Operator

Rot./Lin. Trans. Machining Line, TP -480 1 2 1 0.000 $0.00 $35.70 $250.00 $500.00 $0.00 -$0.07 -$1.04 -$1.12 0.00% 0.00% 0.

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

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

0 0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap SG&A P

T1 or OEM Total Manufacturing Cost: -$0.09 $0.10 $0.76 $0.77 $0.08 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.06 $

Base Cost Impact to Vehicle: -$0.09 $0.10 $0.76 $0.77 $0.08 $0.06 $

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

38,298

10

M

"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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Note, both the Mini and Chrysler GEMA pistons have anodized top ring groove and a dry-film skirt coating.

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 5 of 7
Piston0304 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Piston - Engine, Machined Part Number: 0304-N0101-01 Weekly Component Volume: P

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) P

R

(D

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

38,298

10

M

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Cost per 

Piece

Total 

Amount

Lump 

Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/ 

Racks Required

Rack

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 18,000,000 60 5.00% $0 250 

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

Ot

Pac

Pri

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

Packaging Cost Total: $0.000

 PACKAGING CALCULATIONS: Packaging Type: NO CHANGE TO PACKAGINGPart Size:Parts/Layer:Number of Layers:

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 6 of 7
Engine Assembly 0300 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly of Crank Drive Subsystem Components Part Number: 0300-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) 

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

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

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

1A Shaft - Crank 0301-N0101-01 1 (OEM Mark-up included in Crankshaft Worksheet) 

2A Rod Subassembly - Connecting 0303-N0101-01 4 SAC 3A Piston - Engine, Machined 0304-N0101-01 4 SAC 4A Ring/Clip - Piston Pin Retainer 0304-N0101-02 8 S 5A Pin- Piston 0304-N0101-03 4

GEMA 15Cr3(SAE5015) Case HardenedMini 31CrMoV9 Nitrided

S 

6A Compression Ring - Piston, Top 0304-N0101-04 4 S 7A Compression Ring - Piston, 2nd 0304-N0101-05 4 S 8A Spacer/Expander/Coil Spring - Oil Ring, Piston 0304-N0101-07 4 S 9A Rail(s) - Oil Ring, Piston 0304-N0101-08 4 S 

10A Bearing - Connecting Rod to Crank Shaft 0390-N0101-01 8 AlSn20Mn Base, AlSn10Ni Turbo DI S 

0 0 0 0 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $12.27 $0.00 $0.00 $12.27 $0.00 $0.00 

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

(SAC) &T1 or OEM Mark-Up Values: (6.58) ----- ----- ----- $0.00 $0.00 

Base Cost Impact to Vehicle: $5.69 $0.00 $0.00 $5.69 $0.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/ 

Racks Required

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 250 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: No Changes Required to PackagingPart Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

No impact to engine assembly. Assume wrist pin retaining clip labor/burden add would be offset by labor/burden press fit pin design.

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 7 of 7
Appendix G.1 - Subsystem 04

Counter Balance Subsystem

 Case Study #0101

MAQS Worksheets

File:Counter Balance, 031908.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-04, 1 of 4
Balance Shaft Subassembly 0401 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Balance Shaft Assembly ( Part of Oil Pump Assembly) Part Number: 0401-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Mutiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) 

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

1A Upper and Lower Housing assembly Machining 0401-B0101-11-01 1 Assemble upper and lower housings, machine bearings. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 2 1 8 0.000 $0.00 $35.51 $15.00 $120.00 $0.00 $0.30 $0.50 $0.80 0.00% 0.00% 2A Balance Shaft Long and Short 0401-B0101-06/07 2 Press Gears onto balance shafts. (1 of each shaft type) T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 1 2 1 0.000 $0.00 $35.51 $15.00 $30.00 $0.00 $0.15 $0.13 $0.27 0.00% 0.00% 3A Final Assembly of Balance Shaft Assembly 0401-B0101-01 1 Assemble Shafts into Houisng and rundown fasteners. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 4 1 5 0.000 $0.00 $35.51 $15.00 $75.00 $0.00 $0.59 $0.31 $0.90 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Bottom Housing Casting 0401-B0101-03-1-1 1 Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 112 1 1 1 2.351 $1.10 $43.52 $100.05 $100.05 $2.59 $0.39 $0.89 $3.87 5.00% 6.50% 1B Bottom Housing Casting 0401-B0101-03-1 1 Machine Casting T2/T3 Diecast, MSMC Not Applicable CNC Operator CNC Machining, LMC 115 1 1.5 1 0.000 $0.00 $35.70 $25.00 $37.50 $0.00 $0.31 $0.33 $0.64 5.00% 6.50% 2A Top Housing Balance Shaft Casting 0401-B0101-08-1-1 1 Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 111 1 1 1 2.609 $1.10 $43.52 $100.05 $100.05 $2.87 $0.39 $0.90 $4.17 5.00% 6.50% 2B Top Housing Balance Shaft 0401-B0101-08-1 1 Machine Casting T2/T3 Diecast, MSMC Not Applicable CNC Operator CNC Machining, LMC 114 1 2 1 0.000 $0.00 $35.70 $25.00 $50.00 $0.00 $0.31 $0.44 $0.75 5.00% 6.50% 3A Balance Shaft Short Casting 0401-B0101-06-1-1-1 1 Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 242 3 1 1 1.721 $0.35 $43.52 $100.06 $100.06 $0.60 $0.54 $0.41 $1.56 5.00% 6.50% 3B Balance Shaft Short Casting 0401-B0101-06-1-1-1 1 Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 242 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.41 $0.61 0.50% 6.50% 

3C Balance Shaft Short Machined 0401-B0101-06-1-1 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC 113 0.5 1.5 1 0.000 $0.00 $35.70 $75.00 $112.50 $0.00 $0.16 $1.00 $1.16 0.50% 6.50% 3D Balance Shaft Short Machined 0401-B0101-06-1-1 1 Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC 132 0.5 1.25 1 0.000 $0.00 $35.70 $65.00 $81.25 $0.00 $0.13 $0.61 $0.75 0.50% 6.50% 

3E Balance Shaft Short Machined 0401-B0101-06 1 Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC 120 0.5 1 1 0.000 $0.00 $35.70 $25.00 $25.00 $0.00 $0.15 $0.21 $0.36 0.50% 6.50% 4A Balance Shaft Short Casting 0401-B0101-07-1-1-1 1 Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 226 3 1 1 2.242 $0.35 $43.52 $100.06 $100.06 $0.78 $0.58 $0.44 $1.80 5.00% 6.50% 4B Balance Shaft Short Casting 0401-B0101-07-1-1-1 1 Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 242 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.41 $0.61 0.50% 6.50% 

4C Balance Shaft Short Machined 0401-B0101-07-1-1 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC 114 0.5 2.25 1 0.000 $0.00 $35.70 $75.00 $168.75 $0.00 $0.16 $1.48 $1.64 0.50% 6.50% 4D Balance Shaft Short Machined 0401-B0101-07-1-1 1 Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC 142 0.5 1.3 1 0.000 $0.00 $35.70 $65.00 $84.50 $0.00 $0.13 $0.60 $0.72 0.50% 6.50% 

4E Balance Shaft Short Machined 0401-B0101-07 1 Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC 120 0.5 1 1 0.000 $0.00 $35.70 $25.00 $25.00 $0.00 $0.15 $0.21 $0.36 0.50% 6.50% 5A Gear Balance Shaft 0401-B0101-06-2-1 2 Machine Blank & Hob Teeth (Same process for both Gears) T2/T3 CNC Turning, MSMC LC-Steel-1215, Bar CNC Operator Balancing, MLS, LMC 235 2 4.5 1 0.000 $0.62 $35.70 $25.00 $112.50 $0.00 $0.30 $0.48 $0.78 0.50% 6.50% 5B Gear Balance Shaft 0401-B0101-06-2-1 2 Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 360 1 1 1 0.000 $0.00 $46.52 $50.00 $50.00 $0.00 $0.13 $0.14 $0.27 0.50% 6.50% 

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

1A Dowel Upper to lower housing alignment 0401-B0101-04 2 S 

2A Bearing Shell Balance Shaft 0401-B0101-05 4 S 3A Bolt Balance Shaft Housing 0401-B0101-09 6 S 4A Cap Shaft Close out 0401-B0101-10 2 S 

0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $8.53 $5.83 $10.65 $25.01 $0.68 $1.37 

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.14 $1.85 

Base Cost Impact to Vehicle: $8.53 $5.83 $10.65 $25.01 $0.82 $3.22 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix, G.1-04, 2 of 4
Balance Shaft Subassembly 0401 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Balance Shaft Assembly ( Part of Oil Pump Assembly) Part Number: 0401-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Mutiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/ 

Racks Required

Rack/Pallet Investment Amortization: $0.053 $105,000 0.00% 2,250,000 60 5.00% $420 250 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.053

 PACKAGING CALCULATIONS: Consider additional volume as result of Balance Shaft subassembly:Packaging Type: Option #2Part Size: 190x220 x120Parts/Layer: 5 x 5Number of Layers:7

File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix, G.1-04, 3 of 4
Engine Assembly 04 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly of Balance Shaft Assembly Part Number: Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Mutiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

Mount Balance Shaft Assembly to Engine 0401-B0101-01 1 Install Balance Shaft Assembly to block, 4 Bolts. OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 212 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.39 $0.71 $1.10 0.00% 0

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

1A Bolt - Balance Shaft Assembly Mount to Block PC 12.9 4 (Packaging Included in Cost) S 

2A Balance Shaft Assembly ( Part of Oil Pump Assembly) 0401-B0101-01 1 SAC 

0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $34.84 $0.39 $0.71 $35.95 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (33.01) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $1.83 $0.39 $0.71 $2.93 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-04, 4 of 4
Appendix G.1 - Subsystem 05

Cylinder Block Subsystem

 Case Study #0101

MAQS Worksheets

File:Cylinder Block 05, 032509.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-05, 1 of 8
Cylinder Block 0501 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Cylinder Block Assembly - Machined w. Studs, Plugs, etc. Part Number: 0501-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 0501-N0101-01 (Mini Cooper) 1 Upper cylinder block machining OEM Not Applicable CNC Operator-OEM CNC Milling, LS, HC 135 0.25 0.000 $0.00 $68.07 $250.00 $0.00 $0.13 $1.86 $1.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.98 $1.981B Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 0501-B0101-01 ( Chrysler GEMA) 1 Machining operation adds for mounting balance shaft assembly. OEM Not Applicable CNC Operator-OEM CNC Milling, LS, HC -288 0.25 0.000 $0.00 $68.07 $250.00 $0.00 -$0.06 -$0.87 -$0.93 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.93 -$0.93

1C Cylinder Block Subassembly - Cast 0501-N0101-03 1

Main Cooper Block minus liners =29.19Chrysler GEMA Block minus liners = (33.655 + 2.08)

OEM Aluminum-A380, Cast Not Applicable Not Applicable 89 0 -6.545 $1.10 $0.00 $0.00 -$7.20 $0.00 $0.00 -$7.20 5.00% 0.00% 0.00% 0.00% 5.00% -$0.36 -$7.56 -$7.56

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.00

Purchase Part - High Impact Item (Full Cost Mapping)

1A Cylinder Liners - Cast Iron

0501-N0101-04

4

Mini Cooper Liners = 1.9 lbs/liner, Chrysler GEMA Engine = 2.44lbs/liner

OEM Nodular Iron, Cast Not Applicable Not Applicable 

450 0 -0.540 $0.35 $0.00 $0.00 -$0.19 $0.00 $0.00 -$0.19 0.30% 6.00% 4.00% 0.00% 10.30% -$0.02 -$0.21 -$0.83

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

0 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up -$7.34

T1 or OEM Total Manufacturing Cost: -$7.96 $0.07 $0.99 -$6.90 -$0.36 -$0.05 -$0.03 $0.00 -$0.44 -$7.34

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.05 -$0.51 -$0.59 $0.00 -$1.15

Base Cost Impact to Vehicle: -$7.96 $0.07 $0.99 -$6.90 -$0.41 -$0.56 -$0.62 $0.00 -$1.59 -$8.49 

Packaging Cost: $0.00

Net Cost Impact to Vehicle: -$8.49

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS

1 

450,000 

9,574

47 

450,000 

"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.

3

1

Timing Chain Cover Adds 3.98 lbs to Chrysler GEMA Head, Block, Girdle. Divided by coverage contribution:Head 130/450 = 28.9% or 1.15lbsBlock = 235/450 = 52.2% or 2.08 lbsGirdle = 85/450 = 18.9% or 0.75Mini Cooper has integrated Cover in Head/Block/Bead Plate

NA

Assume casting speed for Chrysler and Mini Cooper Block will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

Assume processing speed for Chrysler and Mini Cooper liners will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

NA

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 2 of 8
Cylinder Block 0501 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Cylinder Block Assembly - Machined w. Studs, Plugs, etc. Part Number: 0501-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS

1 

450,000 

9,574

47 

450,000 

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

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

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 CANegligible Affect 

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 3 of 8
Bed Plate 0503 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bed Plate Assembly - Machined w. Studs, Plugs, etc. Part Number: 0503-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

A1.1 Bed Plate Subassembly - Cast

0503-N0101-02

1 Bed Plate casting OEM Aluminum-A380, Cast Not Applicable Not Applicable 107 0 -3.663 $1.10 $0.00 $0.00 -$4.03 $0.00 $0.00 -$4.03 5.00% 0.00% 0.00% 0.00% 

#DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 

0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Bearing Cap - Bolt Through - Insert, Steel 0503-N0101-03 5 Main Bearing Caps, Cast S Nodular Iron, Cast Not Applicable Not Applicable 554 0 -0.190 $0.35 $0.00 $0.00 -$0.07 $0.00 $0.00 -$0.07 5.00% 6.00% 4.00% 0.00% 1

0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 1

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

S

A

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"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.

Mini Cooper Bed Plate integrated Bearing Cap Weight = 18.01 lbsChrysler Girdle has non integrated bearing capsWeight of Girdle =17.423+ Cover Contribution 0.75 -Oil Filter Inlet 0.25 lbs = 17.923Weight of Caps = 0.94/bs/CapRatio of Cap/(Cap+Girdle) = 20.8% Therefore for Mini Cooper assumption is that 20.8% of Bedplate weight are for Bearing Caps, Thus the following calculations are made:Weight of Base Bed Plate Material = 79.2%x18.01 = 14.26 lbsWeight of Bearing Caps = 20.8%x18.01 = 3.75 lbs

Assume casting speed for Chrysler and Mini Cooper Bed Plate will be approximately same. Thus no additional Labor or Burden costs were accounted for.

NA

Assume casting speed for Chrysler and Mini Cooper Bearing Caps will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

NA

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 4 of 8
Bed Plate 0503 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bed Plate Assembly - Machined w. Studs, Plugs, etc. Part Number: 0503-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

0 

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

M

T1 or OEM Total Manufacturing Cost: -$4.36 $0.00 $0.00 -$4.36 -$0.22 -$0.02 -$0.01 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 1

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.03 -$0.32 -$0.37 $0.00 

Base Cost Impact to Vehicle: -$4.36 $0.00 $0.00 -$4.36 -$0.25 -$0.34 -$0.38 $0.00 

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

S

C

I

Re

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

Pa

Expendable Packaging in Piece Cost: $0.00 $1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.000

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 5 of 8
Piston Cooling 0504 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Squirter - Oil, Piston Cooler & Retainer Part Number: 0504-N0101-01/02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Bolt - Piston Cooler Valve/Retainer 0504-N0101-02 1 Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC 206 0.5 0.350 $1.00 $35.51 $100.19 $0.35 $0.09 $0.49 $0.92 0.30% 6.00% 4.00% 0.00% 102A Squirter - Oil, Piston Cooler 0504-N0101-01 1 Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC 240 0.5 0.300 $1.00 $35.51 $100.19 $0.30 $0.07 $0.42 $0.79 0.30% 6.00% 4.00% 0.00% 10

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

Su

Ac

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

Ma

T1 or OEM Total Manufacturing Cost: $0.65 $0.16 $0.90 $1.71 $0.01 $0.10 $0.07 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.11 $0.08 $0.00 $

Base Cost Impact to Vehicle: $0.65 $0.16 $0.90 $1.71 $0.01 $0.22 $0.14 $0.00 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 18,000,000 60 5.00% $0 460 500 

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

O

Pal

Expendable Packaging in Piece Cost: $0.01 $0.00 0 $0.00 0 $2.50 2 $0.00 0 $0.00 

Packaging Cost Total: $0.010

10

38,298

47

450,000

4

1,800,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 6 of 8
Bearing Elements 0590 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bearings & Thrust Shims - Crankshaft, Part Number: 0590-N0101-01/02/03 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

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

Bearing - Crankshaft, 1/2 Bearing (Top) 0590-N0101-01 5 S Bearing/Shim - Crankshaft Thrust 0590-N0101-02 2 S Bearing - Crankshaft, 1/2 Bearing (Bottom) 0590-N0101-03 5 S 

0 0 0 0 0 0 0 

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

T1 or OEM Total Manufacturing Cost: $2.13 $0.00 $0.00 $2.13 $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: 0.00 ----- ----- ----- $0.00 $0.00 $0.00 $0.00 

Base Cost Impact to Vehicle: $2.13 $0.00 $0.00 $2.13 $0.00 $0.00 $0.00 $0.00 

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

Expendable Packaging in Piece Cost: $0.00 $1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COS

1 

450,000 

9,574

47 

450,000 

"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 

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 7 of 8
Engine Assembly-05-- Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Cylinder Block Components to Engine Part Number: Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = Material + Labor 

+ Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

Squirter - Oil, Piston Cooler - Assembly 0504-N0101-01 4 Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC 800 1 0.000 $0.00 $83.31 $150.19 $0.00 $0.10 $0.19 $0.29 0.00% 0.00% 0.00% 0.00% 0Squirter - Oil, Piston Cooler - Assembly 0504-N0101-01 4 Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC 1440 1 0.000 $0.00 $83.31 $150.19 $0.00 $0.06 $0.10 $0.16 0.00% 0.00% 0.00% 0.00% 0

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

S

A

Squirter - Oil, Piston Cooler & Bolt - Piston Cooler Valve/Retainer 0504-N0101-01/02 4 SAC $Bearing Set (Upper/Lower/Thrust Shim) 0590-N0101-01/02/03 1 (UPGRADE SET) SAC $

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

Ma

T1 or OEM Total Manufacturing Cost: $10.51 $0.65 $1.17 $12.33 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15

(SAC) &T1 or OEM Mark-Up Values: (10.51) ----- ----- ----- $0.09 $0.86 $0.99 $0.00 $

Base Cost Impact to Vehicle: $0.00 $0.65 $1.17 $1.82 $0.09 $0.86 $0.99 $0.00 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"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.

Pallet OptionsOption1: 48"(122cm)x45"(114cm)x34"(86cm)Investment $200 US funds (Mike S.)Assume Plastic Returnables Last 5 YearsOption2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)Investment $20K for toolPiece Price, Pallet Base $100/BasePiece Price, Tier Pad $40/PadCardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 8of 8
Appendix G.1 - Subsystem 06

Cylinder Head Subsystem

 Case Study #0101

MAQS Worksheets

File:Cylinder Head 06, 032009-2.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-06, 1 of 8
Cylinder Head 0601 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Cylinder Head Assembly - Machined w. Studs, Plugs, etc. Part Number: 0601-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Cylinder Head - Machined w/o. Studs, Valves, etc. 0601-N0101-01 1 Cylinder head machining, plug assembly & test OEM Not Applicable CNC Operator-OEM CNC Milling, LS, HC 83 0.25 0.000 $0.00 $68.07 $250.00 $0.00 $0.21 $3.03 $3.24 0.00% 0.00% 0.00% 0.00% 0

1B Cylinder Head - Heat Treat 0601-N0101-02 1

T6 Heat Treat, only consider solution step (quench and artificial age for T6 and T5 approx. estimated to have same cost impact)

OEM Not Applicable Heat Treat Operator-OEM Heat Treat, MLS, MHC 81 0.25 0.000 $0.00 $137.35 $250.00 $0.00 $0.42 $3.08 $3.50 0.00% 0.00% 0.00% 0.00% 0

1C

Cylinder Head Subassembly - CastMini Cooper

0601-N0101-02-01 1 Cylinder head casting & rough machining OEM Aluminum-356-T6, Cast Not Applicable Not Applicable 89 0 29.01 $1.20 $0.00 $0.00 $34.81 $0.00 $0.00 $34.81 5.00% 0.00% 0.00% 0.00% 5

1D

Cylinder Head Subassembly - CastChrysler

0601-N0101-02-01 1 Cylinder head casting & rough machining OEM Aluminum-A319-T5, Cast Not Applicable Not Applicable 89 0 -30.99 $1.15 $0.00 $0.00 -$35.64 $0.00 $0.00 -$35.64 0.00% 0.00% 0.00% 0.00% 0

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0

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

S

A

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"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.

Mini Cooper Head = 30.33- (M8x60 studs x 15 ) 0.69 - Back Support Cap 0.61 = 29.03lbsChrysler GEMA Head = 30.64 - (Valve Guides Intake and Exhaust) 0.53 - (2 M8 Studsx80) 0.12 and (2 M10 Studs x60) 0.15 + (Timing Chain Cover Contribution) 1.15 = 29.84

Assume casting speed for Chrysler and Mini Cooper Heads will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

5% Added Scrap Cost For A356 

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 2 of 8
Cylinder Head 0601 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Cylinder Head Assembly - Machined w. Studs, Plugs, etc. Part Number: 0601-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

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

Ma

T1 or OEM Total Manufacturing Cost: -$0.83 $0.63 $6.11 $5.91 $1.74 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.05 $0.54 $0.61 $0.00 $

Base Cost Impact to Vehicle: -$0.83 $0.63 $6.11 $5.91 $1.79 $0.54 $0.61 $0.00 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 0.00% $0 0 1 

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

O

Pal

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

Packaging Cost Total: $0.000

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 3 of 8
Valve Seat 0602 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Seat - Intake Valve, Seat - Exhaust Valve, Part Number: 0602-N0101-03/04 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

S

A

1A Seat - Intake Valve 0602-N0101-03 8 Material difference S $2A Seat - Exhaust Valve 0602-N0101-04 8 Material difference S $

$

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

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

Base Cost Impact to Vehicle: $0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 36,000,000 60 0.00% $0 0 1 

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

O

Pal

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

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

8 

3,600,000 

76,596

47 

450,000 

"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.

Absolute Cost for Premium Valve SeatsIntake Valve, COMO 1207 => $0.18/ValveExhaust Valve, AR20 => $0.25/ValveBenchmark data from Munro on Baseline Intake and Exhaust Valve Seat $0.16 and $0.22

SETS

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 4 of 8
Bearing Caps 0606 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Cap, Head (Fuel Pump & Vacuum Mount) Part Number: 0606-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-01 1 CNC Machining S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC 240 0.5 0.000 $0.00 $43.52 $100.05 $0.00 $0.09 $0.42 $0.51 0.00% 0.00% 0.00% 0.00% 01B Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-02 1 Die casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 240 0.5 0.610 $1.10 $43.52 $100.05 $0.67 $0.09 $0.42 $1.18 0.00% 0.00% 0.00% 0.00% 0

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

Ma

T1 or OEM Total Manufacturing Cost: $0.67 $0.18 $0.83 $1.69 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.11 $0.10 $0.04 $

Base Cost Impact to Vehicle: $0.67 $0.18 $0.83 $1.69 $0.01 $0.11 $0.10 $0.04 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.032 $64,079 0.00% 2,250,000 60 5.00% $5,140 12 4608 

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

O

Pal

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

Packaging Cost Total: $0.032

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appnedix G.1-06, 5 of 8
Sealing Elements 0685 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Gasket - Cylinder Head to Block Part Number: 0685-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

S

A

Gasket - Cylinder Head to Block 0685-N0101-01 1 Change from 2 to 3 layer gasket S $

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $1.46 $0.00 $0.00 $1.46 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

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

Base Cost Impact to Vehicle: $1.46 $0.00 $0.00 $1.46 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"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.

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 6 of 8
Engine Assembly -06-- Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Cylinder Head Components to Engine Part Number: NA Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Cap, Head (Fuel Pump & Vacuum Mount)0606-N0101-03-01 1 Head and cam assembly OEM Not Applicable Not Applicable Not Applicable 150 0 0.000 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0

1B Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-01 1 Head & Cap Machining OEM Not Applicable Not Applicable Not Applicable 217 0.25 0.000 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0

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

S

A

1A Seat - Intake/Exhaust Valves 0602-N0101-03 8 Material difference SAC $2A Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-01 1 Added Part SAC $3A Bolt - Cap Bearing, Camshaft 0680-N0101-01 4 Added Part S $4A Gasket - Cylinder Head to Block 0685-N0101-01 1 Modified Part SAC $5A Bolt - Manifold, Exhaust 0680-N0101-10 10 510 Stainless or A286 Inconel S $

0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $10.11 $0.00 $0.00 $10.11 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (6.19) ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $

Base Cost Impact to Vehicle: $3.92 $0.00 $0.00 $3.92 $0.00 $0.00 $0.00 $0.00 $

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"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.

NOTES:Did not add any additional costs to add Cap, Head (Fuel Pump & Vacuum Mount). Assumption is additional labor& burden would be negligible in having existing automated process. Machining for O/S face of Cap, Head (Fuel Pump & Vacuum Mount) covered as part of Cylinder Head Machining.

Stainless Steel Exhaust Manifold Hanger Studs: Upgrade to Stainless: Estimated base stud $0.35 and Stainless stud $0.70310/316 (Studs on Mini are Magnetic)410 series good for high temp fastener application not recommended for use w. Aluminum due to Galvanic Action510 Series Stainless or A286 (25.5Ni/14.75Cr)

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 7 of 8
Engine Assembly -06-- Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Cylinder Head Components to Engine Part Number: NA Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 8 of 8
Appendix G.1 - Subsystem 07

Valve Train Subsystem

 Case Study #0101

MAQS Worksheets

File:Valve Trains 07, 032609.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-07, 1 of 4
Valves Int.0701 & Exh.0702 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Valve - Intake & Valve - Outlet Part Number: 0701-N0101-01 & 0702-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

Valve - Inlet 0701-N0101-01 1

Intake valves would need to be upgraded - typical upgrade would be from nitrided JIS SUH11 (Fe-1.5Si, 8.5Cr, 0.5C) to Silichrome

S 

Valve - Outlet 0702-N0101-01 1

Exhaust valves would need to be upgraded - typical upgrade would be from nitrided JIS SUH 35 (Fe, 9Mn, 21Cr 4Ni, 0.5C and 0.4N) to Inconel head and Silichrome stem. Exhaust valves on Mini Cooper Turbo DI are Sodium filled as well. This design approach is not considered preferred and thus will note be included in cost analysis.

S 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.08 $0.00 $0.00 $1.08 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 

Base Cost Impact to Vehicle: $1.08 $0.00 $0.00 $1.08 $0.01 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 36,000,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

76,596

1047

450,000

8

3,600,000

 PACKAGING CALCULATIONS: Packaging Type: NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both 

File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-07, 2 of 4
Camshafts 0706 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Camshaft - Intake Machine & Exhaust Machined Part Number: 0706-N0101-02 & 0706-N0101-11 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Mutiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Camshaft - Intake Machined (MINI) 0706-N0101-02 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 3.886 $0.35 $0.00 $0.00 $0.00 $1.36 $0.00 $0.00 $1.36 0.00% 0

2A Camshaft - Exhaust Machined (MINI) 0706-N0101-11 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 4.256 $0.35 $0.00 $0.00 $0.00 $1.49 $0.00 $0.00 $1.49 0.00% 0

3A Camshaft - Intake Machined (MINI) 0706-B0101-02 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 -4.260 $0.35 $0.00 $0.00 $0.00 -$1.49 $0.00 $0.00 -$1.49 0.00% 0

4A Camshaft - Exhaust Machined (MINI) 0706-B0101-11 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 -4.630 $0.35 $0.00 $0.00 $0.00 -$1.62 $0.00 $0.00 -$1.62 0.00% 0

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

0 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: -$0.26 $0.00 $0.00 -$0.26 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 5.00% 6

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.01 -

Base Cost Impact to Vehicle: -$0.26 $0.00 $0.00 -$0.26 -$0.01 -

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-07, 3 of 4
Engine Assembly 0700 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly Impact from upgraded Valve Train components Part Number: 0700 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

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

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

1A Valves Intake and Exhaust Delta (Mini$-Chrysler$) 8 SAC 

2A Camshafts Exhaust & Intake Delta (Mini$-Chrysler$) 1 SAC 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $10.06 $0.00 $0.00 $10.06 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (10.06) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

No engine assembly cost impact as a result of valve train upgrades.

File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-07, 4 of 4
Appendix G.1 - Subsystem 08

Timing Drive Subsystem

 Case Study #0101

MAQS Worksheets

File:Timing Drives 08 032608.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-08, 1 of 2
Timing Wheels 0801 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Sprocket - Crankshaft, Timing Drive Part Number: 0801-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Mutiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

Sprocket - Crankshaft, Timing Drive 0801-N0101-01 1 (Smart Sprocket royalty, mark- ups included) S 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.60 $0.00 $0.00 $1.60 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $1.60 $0.00 $0.00 $1.60 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type: No Change to PackagingPart Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:Timing Drives 08 032608.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-08, 2 of 2
Appendix G.1 - Subsystem 10

Intake Subsystem

 Case Study #0101

MAQS Worksheets

File:Intake Systems 10 032609.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-10, 1 of 2
Intake Manifold 1001 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Manifold Assembly - Intake Part Number: 1001-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Manifold - Intake, Bottom Half (Mini) 1001-N0101-01-07 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 254 0.5 1 1 1.408 $1.76 $43.52 $150.01 $150.01 $2.48 $0.09 $0.59 $3.15 0.00% 01B Manifold - Intake, Top Half (Mini) 1001-N0101-01-06 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 267 0.5 1 1 0.949 $1.76 $43.52 $150.01 $150.01 $1.67 $0.08 $0.56 $2.31 0.00% 0

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

1A Manifold - Intake, Bottom Half (Chrysler) 1001-B0101-01-07 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS -226 0.5 1 1 -5.036 $1.76 $43.52 $150.01 $150.01 -$8.86 -$0.10 -$0.67 -$9.62 0.00% 01B Manifold - Intake, Top Half (Chrysler) 1001-B0101-01-06 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS -255 0.5 1 1 -3.380 $1.76 $43.52 $150.01 $150.01 -$5.95 -$0.09 -$0.59 -$6.62 0.00% 0

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

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: -$10.66 -$0.01 -$0.10 -$10.78 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6

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

Base Cost Impact to Vehicle: -$10.66 -$0.01 -$0.10 -$10.78 -$0.05 -

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.362 $723,404 0.00% 2,250,000 60 5.00% $340 

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

O

Pa

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

Packaging Cost Total: $0.362

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: MINI COOPER INTAKE MANIFOLD = $0.08Packaging Type: Option #2Part Size: 370x280x170Parts/Layer: 4 x 3 =12Number of Layers: 5

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Equipment, Tooling and Fixturing for friction welding top and bottom sections of intake manifold together would be less expensive for Mini versus GEMA. However since time and burden rate differences would be minor, we have not included the difference as a line code in the quote.

 PACKAGING CALCULATIONS: CHRYSLER GEMA INTAKE MANIFOLD = $0.36Packaging Type: Option #2Part Size: 370x380x225Parts/Layer: 3 x 3Number of Layers:3

File:Intake Systems 10 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-10, 2 of 2
Appendix G.1 - Subsystem 11

Fuel Induction Subsystem

 Case Study #0101

MAQS Worksheets

File:Fuel Induction 11 032709.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-11, 1 of 12
Fuel Rail-1101-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Rail - High Pressure Part Number: 1101-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

Fuel Rail High Pressure 1101-N0101-02 1 Assembly, Braze & Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 288 3 1 10 0.000 $0.00 $35.51 $15.00 $150.00 $0.00 $0.37 $0.52 $0.89 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube - Injector Rail 1101-N0101-02-06 1 Turn & cross Drill T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube CNC Operator CNC Turning, MC 180 0.5 1 1 0.600 $1.65 $35.70 $45.00 $45.00 $0.99 $0.10 $0.25 $1.34 0.00% 02A Threaded Plug Rail Inlet 1101-N0101-02-05 1 Machine & Tap T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Turning, MC 138 1 1.5 1 0.060 $1.65 $35.70 $45.00 $67.50 $0.10 $0.26 $0.49 $0.84 0.00% 03A Boss High Pressure Sensor 1101-N0101-02-03 1 Machine & Tap T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Turning, LMC 164 0.5 1.5 1 0.080 $1.65 $35.70 $100.00 $150.00 $0.13 $0.11 $0.92 $1.16 0.00% 04A Cup Injector Port 1101-N0101-02-01 4 Plating T1 Assembly, Mark-up Applied @ Bottom. Plating, Fuel Rail Plating/Coating Operator Plate/Finish, SMS, MHC 720 1 1 1 0.001 $20.00 $55.17 $125.17 $125.17 $0.02 $0.08 $0.17 $0.27 0.00% 04B Cup Injector Port 1101-N0101-02-01-1 4 Machine & Cross Drill T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Turning, HC 480 2 4 1 0.260 $1.65 $35.70 $75.00 $300.00 $0.43 $0.15 $0.63 $1.20 0.00% 05A Bracket Rail Mounting 1101-N0101-02-02 2 Stamping T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 610 0.5 1 1 0.147 $1.64 $42.18 $100.10 $100.10 $0.24 $0.03 $0.16 $0.44 0.00% 0

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

1A Plug Rail End 1101-N0101-02-04 1 Stainless 304 S 

2A High Pressure Fuel Sensor Assembly 1101-N0101-03 1 Pressure Sensor S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $11.09 $1.81 $5.70 $18.59 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.06 

Base Cost Impact to Vehicle: $11.09 $1.81 $5.70 $18.59 $0.06 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.068 $136,636 0.00% 2,250,000 60 5.00% $2,740 

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

O

Pa

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

Packaging Cost Total: $0.068

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: Option #3, Tote w. Vacuum Form PackPart Size: 300x55x100mmParts/Layer: 8Number of Layers:3

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 2 of 12
Injector-1104-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Injector Assembly - Solenoid, 7 Hole Part Number: 1104-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

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

1A Fuel Injector Assembly 1104-N0101-01 1 Final Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, LC, Base 480 2 1 6 0.000 $0.00 $37.35 $15.00 $90.00 $0.00 $0.16 $0.19 $0.34 0.00% 2A Seal Injector Tip 1104-N0101-01-30 1 Overmold seal @ Injector Tip T1 Assembly, Mark-up Applied @ Bottom. Nylon-HT, Inject. Electromechanical Assembly Mech Assembly, MC, Base 450 1 1 1 0.005 $4.00 $37.35 $30.00 $30.00 $0.02 $0.08 $0.07 $0.17 0.00% 3A Solenoid Body preassembled 1104-N0101-01-10 1 Insert Windings, Ring Locator and Needle Body Assembly into Body Injector and Overmold T1 Assembly, Mark-up Applied @ Bottom. Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base 450 2 1 5 0.030 $1.54 $37.35 $45.00 $225.00 $0.05 $0.17 $0.50 $0.71 0.00% 4A Needle Body Assembly 1104-N0101-01-50 1 Laser weld internal valve body (Sleeve, Needle Body, Tip and Inlet Tube) T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 450 4 1.5 8 0.000 $0.00 $37.35 $30.00 $360.00 $0.00 $0.33 $0.80 $1.13 0.00% 5A Needle Assembly 1104-N0101-01-11 1 Assemble & Press Sleeve T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 450 1 1 4 0.000 $0.00 $37.35 $30.00 $120.00 $0.00 $0.08 $0.27 $0.35 0.00% 6A Needle Injector 1104-N0101-01-13 1 Laser Weld Ball and Seat to Needle T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 514 1 1 3 0.000 $0.00 $37.35 $30.00 $90.00 $0.00 $0.07 $0.18 $0.25 0.00% 7A Metering Valve assembly 1104-N0101-01-16 1 Laser Weld Plate to Valve T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 514 1 1 2 0.000 $0.00 $37.35 $30.00 $60.00 $0.00 $0.07 $0.12 $0.19 0.00% 

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

Purchase Part - High Impact Item (Full Cost Mapping)

1A Body Injector Solenoid 1104-N0101-01-20 1 Machine Body T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 500 0.5 5 1 0.140 $4.56 $35.70 $45.00 $225.00 $0.64 $0.04 $0.45 $1.12 0.50% 2A Sleeve winding to inlet separator 1104-N0101-01-27 1 Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 491 0.5 4.5 1 0.074 $4.56 $35.70 $45.00 $202.50 $0.34 $0.04 $0.41 $0.79 0.50% 3A Sleeve Fuel Inlet 1104-N0101-01-28 1 Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 485 0.5 3.5 1 0.041 $4.56 $35.70 $45.00 $157.50 $0.19 $0.04 $0.33 $0.55 0.50% 4A Body needle 1104-N0101-01-9 1 Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 460 0.5 5.5 1 0.043 $4.56 $35.70 $45.00 $247.50 $0.20 $0.04 $0.54 $0.77 0.50% 5A Inlet Tube 1104-N0101-01-21 1 Cut and Flare T2/T3 Hydro/CNC Form, SSLC S-Steel-304, Tube Forging Operator Cold Forge, LMC 360 0.5 1 1 0.010 $1.65 $38.52 $100.09 $100.09 $0.02 $0.05 $0.28 $0.35 0.30% 6A Spring Seat Lower 1104-N0101-01-14 1 Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 450 0.25 1.5 1 0.0002 $4.56 $35.70 $45.00 $67.50 $0.00 $0.02 $0.15 $0.17 0.50% 7A Needle valve 1104-N0101-01-24 1 Centerless Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 540 0.25 1.5 1 0.000 $0.00 $35.70 $45.00 $67.50 $0.00 $0.02 $0.13 $0.14 0.50% 7B Needle valve 1104-N0101-01-24-01 1 Machine Heat Treat T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 540 0.25 1.5 1 0.002 $4.56 $35.70 $45.00 $67.50 $0.01 $0.02 $0.13 $0.15 0.50% 8A Ball Needle seat 1104-N0101-01-23 1 EDM Mounting Pocket T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 720 0.25 1 1 0.000 $0.00 $35.70 $45.00 $45.00 $0.00 $0.01 $0.06 $0.07 0.50% 8A Ball Needle seat 1104-N0101-01-23 1 Grind/Lap/Wash T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 540 0.25 1.5 1 0.000 $0.00 $35.70 $45.00 $67.50 $0.00 $0.02 $0.13 $0.14 0.50% 8A Ball Needle seat 1104-N0101-01-23 1 Cold Head/Machine/Heat Treat T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator Cold Forge, LMC 720 0.25 1 1 0.0003 $4.56 $35.70 $100.09 $100.09 $0.00 $0.01 $0.14 $0.15 0.50% 9A Metering Valve 1104-N0101-01-18 1 Machined T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 470 0.25 3 1 0.005 $4.56 $35.70 $45.00 $135.00 $0.02 $0.02 $0.29 $0.33 0.50% 

10A Plate Metering Valve 1104-N0101-01-19 1 Stamping T2/T3 Stamp/Form, MSMC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 766 0.25 1 1 0.0002 $1.64 $42.18 $100.10 $100.10 $0.00 $0.01 $0.13 $0.14 0.50% 11A Tip - Injector 1104-N0101-01-08 1 EDM Micro Popping T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, MHC 480 0.5 2 1 0.000 $0.00 $35.70 $150.15 $300.30 $0.00 $0.04 $0.63 $0.66 0.50% 11B Tip - Injector 1104-N0101-01-08-01 1 Metal Injection Molding T2/T3 Powder Metal, LSHC S-Steel-440-MIM Mold/Cast/Sinter Operator Powder Metal, MHC 480 1 1 1 0.002 $13.68 $43.52 $150.14 $150.14 $0.03 $0.09 $0.31 $0.43 0.70% 12A Face seal Injector to head 1104-N0101-01-4-1 1 Powder Metal T2/T3 Powder Metal, SSLC PM-SMF-SS410 Mold/Cast/Sinter Operator Powder Metal, LMC 1440 0.5 1 1 0.005 $4.92 $43.52 $100.14 $100.14 $0.02 $0.02 $0.07 $0.11 0.30% 13A Bracket Injector hold-down 1104-N0101-01-2 1 Stamping T2/T3 Stamp/Form, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 1 1 0.078 $0.78 $42.18 $100.10 $100.10 $0.06 $0.04 $0.17 $0.26 0.50% 

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

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

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

1A Solenoid Windings 1104-N0101-01-22 1 S 

2A Ring winding locator 1104-N0101-01-26 1 S 3A Spring - needle to metering valve 1104-N0101-01-15 1 S 4A Spring Needle Return 1104-N0101-01-12 1 S 5A Sleeve Screen Stop 1104-N0101-01-25 1 S 6A Screen Fuel Inlet 1104-N0101-01-6 1 S 7A circlip face seal retainer 1104-N0101-01-5 1 S 8A Compression limiter - oring 1104-N0101-01-3 1 S 9A O-Ring Injector to rail seal 1104-N0101-01-1 1 S 

0 0 0 0 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 3 of 12
Injector-1104-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Injector Assembly - Solenoid, 7 Hole Part Number: 1104-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

Full Quote Modification Quote Differential Quote (Quote Summary includes 

Material Labor Burden TMC Scrap 

T1 or OEM Total Manufacturing Cost: $2.16 $1.47 $6.44 $10.07 $0.03 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.08 

Base Cost Impact to Vehicle: $2.16 $1.47 $6.44 $10.07 $0.11 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces/ 

Amortization 

Period

Number of 

Service Months 

Interest 

Rate

Cost per Pallet /Rack

Rack/Pallet Investment Amortization: $0.014 $108,680 0.00% 9,000,000 60 5.00% $4,180 

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

P

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

Packaging Cost Total: $0.014

 PACKAGING CALCULATIONS: Packaging Type: Option #3 Tote, 42 Totes/PalletPart Size: 90x55x25 mmParts/Layer per tote: 3 x 8Number of Layers per tote: 9

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 4 of 12
HP-Fuel Pump 1107-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) Part Number: 1107-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Fuel Pump - High Pressure w. Vol. Control Valve 1107-N0101-01 1 Final Assembly Line T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 360 3 1 10 0.250 $0.00 $35.51 $45.00 $450.00 $0.00 $0.30 $1.25 $1.55 0.00% 02A Swash Plate Drive Assembly 1107-N0101-01-09 1 Subassembly Line T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 360 1 1 8 0.000 $0.00 $35.51 $30.00 $240.00 $0.00 $0.10 $0.67 $0.77 0.00% 03A Bellow piston cavity 1107-N0101-01-14 2 Weld Subassembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 300 2 1 4 0.000 $0.00 $35.51 $30.00 $120.00 $0.00 $0.24 $0.40 $0.64 0.00% 04A Bellow Retainer 1107-N0101-01-16 2 Press Orifice Insert onto Bellows Retainer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 600 1 1 1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.06 $0.05 $0.11 0.00% 05A Shaft Drive Adapter 1107-N0101-01-09-6 1 Press Ball, Springs and Insert T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 300 0.5 1 1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.06 $0.10 $0.16 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Housing Fuel Pump 1107-N0101-01-25-1 1 Extrude Housing T2/T3 Cold Forge, MSMC Aluminum-7075-T6, Ext. Extruding/Drawing Operator Cold Forge, MHC 96 2 1 1 1.800 $3.21 $54.35 $150.09 $150.09 $5.78 $1.13 $1.56 $8.47 0.50% 61B Housing Fuel Pump 1107-N0101-01-25-1 1 Machine Housing T2/T3 CNC Milling, LSHC Not Applicable CNC Operator CNC Machining, LMC 121 4 14 1 0.000 $0.00 $35.70 $25.00 $350.00 $0.00 $1.18 $2.88 $4.06 0.70% 7

1C Housing Fuel Pump 1107-N0101-01-25 1 Assemble Ball Plugs T2/T3 Mech. Assembly, SSLC Purchased Parts General Assembly

Mech Assembly, LC, Base

240 1 1 4 0.110 $1.00 $35.51 $15.00 $60.00 $0.11 $0.15 $0.25 $0.51 0.30% 6

2A Bar Stock - Check Valve Assembly 1107-N0101-01-22-1 1 Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, HC 180 0.25 2 1 0.040 $1.65 $37.60 $85.00 $170.00 $0.07 $0.05 $0.94 $1.06 0.30% 62B Check Valve Assembly 1107-N0101-01-22 1 Assemble components T2/T3 Mech. Assembly, SSLC Purchased Parts General Assembly Mech Assembly, MC, Base 277 1 1 2 0.030 $1.00 $35.51 $30.00 $60.00 $0.03 $0.13 $0.22 $0.37 0.30% 63A Retainer Check Valve Assembly 1107-N0101-01-24-1 1 Machining T2/T3 CNC Turning, SSLC Ni-Al-Bronze-630000, Bar Lathe/Turning Operator CNC Turning, LC 144 1 2 1 0.075 $2.44 $37.60 $25.00 $50.00 $0.18 $0.26 $0.35 $0.79 0.30% 64A Plate - Check Valve 1107-N0101-01-20 2 Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator CNC Turning, LC 257 0.5 2 2 0.000 $1.65 $37.60 $25.00 $100.00 $0.00 $0.07 $0.39 $0.46 0.30% 65A Seat - Check Valve Plate 1107-N0101-01-21 2 Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC 250 1 2.5 1 0.005 $1.65 $37.60 $55.00 $137.50 $0.01 $0.15 $0.55 $0.71 0.30% 66A Retainer Check Valve 1107-N0101-01-17 2 Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, HC 251 1 3 1 0.050 $2.44 $37.60 $85.00 $255.00 $0.12 $0.15 $1.02 $1.29 0.30% 67A Bellow piston cavity 1107-N0101-01-14-1 2 Cut and Form Tube Stock T2/T3 Hydro/CNC Form, MSMC Titanium-6AL4V, Bar Cut/Punch/Forming Operator Hydro/CNC Form, MLS, MHC 225 1 1 1 0.010 $34.37 $42.18 $150.12 $150.12 $0.34 $0.19 $0.67 $1.20 5.00% 68A Spring Seat 1107-N0101-01-14-2 2 Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC 235 1 3 1 0.050 $2.44 $37.60 $55.00 $165.00 $0.12 $0.16 $0.70 $0.98 0.30% 69A Top Seat and Sealing Flange 1107-N0101-01-14-3 2 Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC 230 1 3 1 0.110 $2.44 $37.60 $55.00 $165.00 $0.27 $0.16 $0.72 $1.15 0.30% 6

10A Bellow Retainer 1107-N0101-01-16-1 2 Machining T2/T3 CNC Turning, SSLC A-Steel-41XXS, Bar Lathe/Turning Operator S-CNC Turning, MC 231 2 5 1 0.500 $0.78 $37.60 $55.00 $275.00 $0.39 $0.33 $1.19 $1.91 0.30% 611A Piston High pressure pump 1107-N0101-01-11 2 Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC 225 2 4 1.5 0.030 $0.78 $37.60 $55.00 $330.00 $0.02 $0.33 $1.47 $1.82 0.30% 612A Cap Piston contact to swash plate 1107-N0101-01-10 2 Plating T2/T3 Plate/Finish Mech., SSLC Not Applicable Plating/Coating Operator Plate/Finish, SMS, LMC 360 0.5 1 1 0.000 $0.00 $55.17 $100.17 $100.17 $0.00 $0.08 $0.28 $0.35 0.30% 612B Cap Piston contact to swash plate 1107-N0101-01-10 2 Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC 225 1 2 1.5 0.000 $0.78 $37.60 $55.00 $165.00 $0.00 $0.17 $0.73 $0.90 0.30% 613A Casting: Swash Plate Drive Housing 1107-N0101-01-09-2 1 Aluminum Diecast T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 286 0.5 1 1 0.209 $1.10 $43.52 $100.05 $100.05 $0.23 $0.08 $0.35 $0.66 5.00% 613A Swash Plate Drive Housing Machined 1107-N0101-01-09-1 1 Machine Casting T2/T3 CNC Turning, MSMC Not Applicable Mold/Cast/Sinter Operator RTM Turning, HC, PP, Base 300 0.5 1 1 0.000 $0.00 $43.52 $200.00 $200.00 $0.00 $0.07 $0.67 $0.74 0.50% 614A Swash Plate Assy - Cast 1107-N0101-01-09-5-3 1 Iron Casting T2/T3 Perm. Cast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, MHC 286 3 1 1 0.219 $0.35 $43.52 $150.06 $150.06 $0.08 $0.46 $0.53 $1.06 5.00% 614B Swash Plate Assy 1107-N0101-01-09-5-2 1 Machine Casting T2/T3 CNC Turning, MSMC Not Applicable CNC Operator RTM Turning, HC, PP, Base 360 0.5 1 1.2 0.000 $0.00 $35.70 $200.00 $240.00 $0.00 $0.05 $0.67 $0.72 0.50% 6

14C Swash Plate Assy 1107-N0101-01-09-5-1 1 Heat Treat T2/T3 Plate/Finish Mech., SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 250 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.40 $0.59 0.30% 614D Swash Plate Assy 1107-N0101-01-09-5 1 Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator

CNC Turning, MC

124 1 1 1 0.000 $0.00 $35.70 $45.00 $45.00 $0.00 $0.29 $0.36 $0.65 0.50% 6

15A Shaft Drive Adapter PM 1107-N0101-01-09-6-5 1 Press and Sinter T2/T3 Powder Metal, SSLC PM-SMF-Iron Base Mold/Cast/Sinter Operator Powder Metal, LMC 632 1 1 1 0.037 $1.00 $43.52 $100.14 $100.14 $0.04 $0.07 $0.16 $0.26 0.30% 615B Shaft Drive Adapter w/out backlash adjuster 1107-N0101-01-09-6-1 1 Machining T2/T3 CNC Milling, SSLC Not Applicable Mold/Cast/Sinter Operator CNC Machining, LMC 200 0.25 1 2 0.000 $0.00 $43.52 $25.00 $50.00 $0.00 $0.05 $0.25 $0.30 0.30% 617A Mount Bracket HP fuel Pump 1107-N0101-01-03 1 Ground Flat T2/T3 CNC Milling, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC 600 1 1 1 0.000 $0.00 $42.18 $100.13 $100.13 $0.00 $0.07 $0.17 $0.24 0.30% 617B Mount Bracket HP fuel Pump 1107-N0101-01-03-1 1 Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC 391 0.5 1 1 1.080 $0.55 $42.18 $100.13 $100.13 $0.59 $0.05 $0.26 $0.90 0.30% 618A Spacer - Mount Bracket - swash plate retainer 1107-N0101-01-02 1 Fineblanked T2/T3 Fine Blank, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC 600 1 1 1 0.000 $0.00 $42.18 $100.13 $100.13 $0.00 $0.07 $0.17 $0.24 0.30% 618B Spacer - Mount Bracket 1107-N0101-01-02-1 1 Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC 439 0.5 1 1 0.557 $0.55 $42.18 $100.13 $100.13 $0.31 $0.05 $0.23 $0.58 0.30% 619A Diaphragm Temperature Compensating 1107-N0101-01-08 1 Assemble & Test T2/T3 Mech. Assembly, SSLC Purchased Parts Cut/Punch/Forming Operator Mech Assembly, LC, Base 300 1 1 3 0.120 $1.00 $42.18 $15.00 $45.00 $0.12 $0.14 $0.15 $0.41 0.30% 619B Top Stamping Diaphragm Temperature Compensating 1107-N0101-01-08-1 1 Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 621 0.5 1 1 0.042 $0.45 $42.18 $100.10 $100.10 $0.02 $0.03 $0.16 $0.21 0.30% 6

19C Bottom Stamping Diaphragm Temperature Compensating 1107-N0101-01-08-2 1 Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 643 0.5 1 1 0.018 $0.45 $42.18 $100.10 $100.10 $0.01 $0.03 $0.16 $0.20 0.30% 6

20A Fitting Fuel Inlet 1107-N0101-01-06 1 Machine T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC 123 0.5 1.5 1 0.120 $1.65 $37.60 $55.00 $82.50 $0.20 $0.15 $0.67 $1.02 0.30% 6

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 5 of 12
HP-Fuel Pump 1107-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) Part Number: 1107-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

Full Quote Modification Differential Quote (Quote Summary includes 

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

1A 4mm Ball Plug NA 7 Purchase Part B1A 

2A Seat Fuel Outlet Fitting NA 1 Purchase Part B1A 3A Check Ball 1107-N0101-01-22-3 1 Purchase Part B3A 4A Spring Check Ball 1107-N0101-01-22-4 1 Purchase Part B3A 5A Seat Check Ball 1107-N0101-01-22-5 1 Purchase Part B3A 6A Spring Check Valve 1107-N0101-01-23 1 Purchase Part S 7A Seat Check valve spring 1107-N0101-01-18 2 Purchase Part S 8A Spring - Check Valve 1107-N0101-01-19 2 Purchase Part S 9A Spring Bellow return 1107-N0101-01-13 2 Purchase Part S 

10A Pin Guide Pin Guide 2 Purchase Part S 11A O-Ring Bellow OD sealing 1107-N0101-01-15 2 Purchase Part S 12A Tip Insert - Orifice 1107-N0101-01-16-2 2 Purchase Part S 13A Spring HP piston 1107-N0101-01-12 2 Purchase Part S 14A Seal Swash Plate shaft 1107-N0101-01-09-4 1 Purchase Part S 15A Bearing Roller, Swash Plate Shaft 1107-N0101-01-09-8 1 Purchase Part S 16A Bearing Roller Thrust, Swash Plate 1107-N0101-01-09-7 1 Purchase Part S 17A Spring Backlash adjust 1107-N0101-01-09-6-4 2 Purchase Part S 18A Ball Backlash Adjust 1107-N0101-01-09-6-3 2 Purchase Part S 19A Ball Seat/Retainer 1107-N0101-01-09-6-2 2 Purchase Part S 20A O-ring OD Seal to pump housing 1107-N0101-01-09-3 1 Purchase Part S 21A Bolt Mount bracket 1107-N0101-01-01 3 Purchase Part S 22A Oil Swash Plate cavity 1107-N0101-01-26 1 Purchase Part S 23A Spring Stamping Diaphragm Temperature Compensating 1107-N0101-01-08-3 1 Purchase Part B19A 23B Diaphragm Temperature Compensating 1107-N0101-01-08-3-1 1 Purchase Part B19A 

24 Screen Fuel Inlet 1107-N0101-01-07 1 Purchase Part S 25 Solenoid Fuel Pump Control 1107-N0101-01-05 1 Purchase Part S 26 Bolt Control Solenoid - fuel pump 1107-N0101-01-04 2 Purchase Part S 27 Seal - High Pressure Fuel Pump to Cylinder Head 1185-N0101-01 1 Purchase Part S 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $16.99 $8.24 $28.32 $53.55 $0.33 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.41 

Base Cost Impact to Vehicle: $16.99 $8.24 $28.32 $53.55 $0.73 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.111 $221,160 0.00% 2,250,000 60 5.00% $3,880 

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

O

Pa

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

Packaging Cost Total: $0.111

 PACKAGING CALCULATIONS: Packaging Type: Option #3 TotesPart Size: 100x100x100Parts/Layer: 4x2Number of Layers: 3

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 6 of 12
Pipe Assembly 1170-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Pipe Assembly - Fuel, High Pressure, Pump to Rail Part Number: 1170-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Pipe - Fuel, High Pressure, Pump to Rail 1170-N0101-01 1 Assembly Tube Nuts and Flare Tube Ends T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 225 1 1 2 0.000 $0.00 $35.51 $15.00 $30.00 $0.00 $0.16 $0.13 $0.29 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Stock HP pump to rail 1170-N0101-01-01 1 CNC Tube Bending T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 171 0.25 1 1 0.060 $1.65 $42.18 $100.12 $100.12 $0.10 $0.06 $0.58 $0.74 0.00% 02A Tube Nut HP pump to rail 1170-N0101-01-02 2 Screw Machine Hex Bar Stock T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube CNC Operator CNC Turning, LC 288 0.5 2 1 0.088 $1.65 $35.70 $25.00 $50.00 $0.15 $0.06 $0.17 $0.38 0.00% 0

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

0 

0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $0.39 $0.34 $1.06 $1.80 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 

Base Cost Impact to Vehicle: $0.39 $0.34 $1.06 $1.80 $0.01 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.008 $16,117 0.00% 2,250,000 60 5.00% $2,020 

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

O

Pa

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

Packaging Cost Total: $0.008

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: Option #3 PackagingPart Size:=(1/2*(170*70))*50)= 2.975E5mm^3Tote Volume= 508x300x300=45.7E6mm^3Parts/Tote = 150

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 7 of 12
Fuel Rail 1101 - GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Rail Assembly Part Number: 1101-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Fuel Rail Assembly 1101-B0101-01 1 Flow Drill Injector Cups to Rail T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 157 2 1 1 0.000 $0.00 $35.51 $45.00 $45.00 $0.00 $0.45 $0.29 $0.74 0.00% 02A Fuel Rail Assembly 1101-B0101-01 1 Projection Weld Brackets T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $35.51 $15.00 $15.00 $0.00 $0.14 $0.06 $0.20 0.00% 03A Fuel Rail Assembly 1101-B0101-01 1 Assembly end caps and inlet tube and braze weld assembly. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 157 2 1 4 0.000 $0.00 $35.51 $15.00 $60.00 $0.00 $0.45 $0.38 $0.84 0.00% 0

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

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Injector Rail 1101-B0101-01-3 1 Cut to length and back extrude inlet T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 300 1 1 1 0.563 $1.65 $42.18 $100.10 $100.10 $0.93 $0.14 $0.33 $1.40 0.00% 02A End Cap 1101-B0101-01-4 2 Stamp T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 706 0.5 1 1 0.011 $1.64 $42.18 $100.10 $100.10 $0.02 $0.03 $0.14 $0.19 0.00% 03A Cup Injector Port 1101-B0101-01-5 4 Stamp T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 735 0.5 1 1 0.006 $1.64 $42.18 $100.10 $100.10 $0.01 $0.03 $0.14 $0.17 0.00% 04A Bracket Rail Mounting 1101-B0101-01-6 2 Stamp T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 679 0.5 1 1 0.095 $1.64 $42.18 $100.10 $100.10 $0.16 $0.03 $0.15 $0.33 0.00% 05A Inlet Tube 1101-B0101-01-7 1 Bend & Form T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 600 0.5 1 1 0.029 $1.65 $42.18 $100.12 $100.12 $0.05 $0.04 $0.17 $0.25 0.00% 0

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

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

0 

0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.36 $1.46 $2.35 $5.18 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6

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

Base Cost Impact to Vehicle: $1.36 $1.46 $2.35 $5.18 $0.02 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 8 of 12
Fuel Rail 1101 - GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Rail Assembly Part Number: 1101-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.069 $138,963 0.00% 2,250,000 60 5.00% $4,180 

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

O

Pa

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

Packaging Cost Total: $0.069

 PACKAGING CALCULATIONS: Packaging Type: Option #3Part Size: Parts/Layer: 1X12Number of Layers 3

Pallet OptionsOption1: 48"(122cm)x45"(114cm)x34"(86cm)Investment $200 US funds (Mike S.)Assume Plastic Returnables Last 5 YearsOption2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)Investment $20K for toolPiece Price, Pallet Base $100/BasePiece Price, Tier Pad $40/PadOption3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)Package: 8 Layers of 6 on single Pallet Base.Cost per Tote: $75/ToteCost per Base $100/BaseCardboard 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, $5.00Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 9 of 12
Injector-1104-GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Injector Assembly - Low Pressure, 4 Hole Part Number: 1104-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Injector Tip Assembly 1104-B0101-01-80 1 Assemble Injector Tip T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly

Mech Assembly, MC, Base

1800 0.5 1 4 0.000 $0.00 $35.51 $30.00 $120.00 $0.00 $0.01 $0.07 $0.08 0.00% 0

2A Injector Needle Assembly 1104-B0101-01-70 1 Assemble Injector Needle T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 480 0.5 2 3 0.000 $0.00 $35.51 $30.00 $180.00 $0.00 $0.04 $0.38 $0.41 0.00% 03A Needle Body Assembly 1104-B0101-01-71 1 Assemble Injector Needle T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly

Mech Assembly, MC, Base

480 2 2 7 0.000 $0.00 $35.51 $30.00 $420.00 $0.00 $0.15 $0.88 $1.02 0.00% 0

4A Solenoid Body Overmold 1104-B0101-01-72 1 Overmold Solenoid Body T1 Assembly, Mark-up Applied @ Bottom. Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base 450 2 2 1 0.030 $1.54 $37.35 $45.00 $90.00 $0.05 $0.17 $0.20 $0.41 0.00% 05A Final Assembly 1104-B0101-01-73 1 Final Assembly & Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 480 2 2 6 0.000 $0.00 $35.51 $45.00 $540.00 $0.00 $0.15 $1.13 $1.27 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Inlet 1104-B010101-01-21 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator CNC Turning, LC 471 2 5.5 1 0.035 $0.78 $35.70 $25.00 $137.50 $0.03 $0.15 $0.29 $0.47 0.50% 62A Inlet Sleeve Adaptor Stamped 1104-B0101-01-50 1 Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 1200 0.5 1 1 0.008 $0.78 $42.18 $125.10 $125.10 $0.01 $0.02 $0.10 $0.13 0.30% 63A Coupler Fuel Inlet 1104-B0101-01-28 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, LC 450 1 4 1 0.023 $0.78 $35.70 $35.00 $140.00 $0.02 $0.08 $0.31 $0.41 0.50% 64A Body, Needle 1104-B0101-01-09 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, LC 465 1 4 1 0.049 $0.78 $35.70 $35.00 $140.00 $0.04 $0.08 $0.30 $0.42 0.50% 65A Can Solenoid Housing 1104-B0101-01-51 1 Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.5 1 1 0.043 $0.78 $42.18 $100.10 $100.10 $0.03 $0.03 $0.14 $0.20 0.30% 66A Needle Valve 1104-B0101-01-24 1 Stamped/Forged T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 1 1 0.005 $0.78 $42.18 $100.10 $100.10 $0.00 $0.04 $0.17 $0.21 0.30% 67A Needle Valve Seat 1104-B0101-01-52 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, LC 643 0.5 2.5 1 0.005 $0.78 $35.70 $35.00 $87.50 $0.00 $0.03 $0.14 $0.17 0.50% 68A Bracket Injector Hold down 1104-B0101-01-02-01 1 Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1800 0.25 1 1 0.021 $0.65 $42.18 $100.10 $100.10 $0.01 $0.01 $0.06 $0.07 0.30% 68B Bracket Injector Hold down 1104-B0101-01-02 1 Heat Treat & Plate T2/T3 Heat Treat, SSLC General Underhood Plating Plating/Coating Operator Plate/Finish, SMS, LMC 1800 0.5 1 1 0.001 $15.00 $55.17 $100.17 $100.17 $0.02 $0.02 $0.06 $0.09 0.30% 69A Injector Tip Housing 1104-N0101-01-08 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, MC 450 1 4.5 1 0.003 $0.78 $35.70 $55.00 $247.50 $0.00 $0.08 $0.55 $0.63 0.50% 6

10A Plate - Injector Tip 1104-N0101-01-08-02 1 Stamp T2/T3 CNC Turning, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 3600 0.25 1 1 0.000 $0.78 $42.18 $100.10 $100.10 $0.00 $0.00 $0.03 $0.03 0.50% 610B Plate - Injector Tip 1104-N0101-01-08-01 1 Laser Injector Holes T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, LMC 3600 0.25 1 1 0.000 $0.00 $35.70 $125.15 $125.15 $0.00 $0.00 $0.03 $0.04 0.50% 611A Tip Relief Plate 1104-B0101-01-70 1 Stamp T2/T3 Stamp/Form, SSLC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 2057 0.25 1 1 0.000 $0.78 $42.18 $100.10 $100.10 $0.00 $0.01 $0.05 $0.05 0.30% 6

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

1A Sleeve Screen-Screen Stop 1104-B0101-01-25 1 S 

2A Screen, Fuel Inlet 1104-B0101-01-06 1 S 3A Retainer Metering valve, Upper Spring Seat 1104-B0101-01-17 1 S 4A Ball Needle Seat 1104-B0101-01-23 1 (Used Pricing from Mini Injector) S 5A Spring - Needle Return 1104-B0101-01-12 1 S 6A Solenoid Winding Assembly 1104-N0101-01-22 1 S 7A O-Ring Injector to Rail Seal 1104-B0101-01-61 1 S 8A O-Ring Injector to Head 1104-B0101-01-62 1 S 9A Sleeve Injector Head 1104-B0101-01-63 1 S 

10A Injector Slip Washer 1104-B0101-01-64 1 S 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.03 $1.04 $4.86 $6.93 $0.01 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

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

Base Cost Impact to Vehicle: $1.03 $1.04 $4.86 $6.93 $0.06 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 10 of 12
Injector-1104-GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Injector Assembly - Low Pressure, 4 Hole Part Number: 1104-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.012 $97,961 0.00% 9,000,000 60 5.00% $4,420 

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

O

Pa

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

Packaging Cost Total: $0.012

 PACKAGING CALCULATIONS: Packaging Type: Option #3 TotePart Size: 90x55x25 mmParts/Layer: 3 x 8Number of Layers: 9

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 11 of 12
Engine Assembly-1100 R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Fuel Induction Components to Engine Part Number: 1100 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Fuel Rail - High Pressure 1101-N0101-02 1

Install Fuel Rail to Cylinder Head (Two Additional Fasteners Over Base GEMA Engine)

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 257 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.32 $0.58 $0.91 0.00% 0

2A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-01 4

Install Fuel Injectors to Cylinder Head, Considered Wash to Base Engine

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable Not Applicable Not Applicable 451 1 1 1 0.000 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 0.00% 0

Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) 1107-N0101-01 1 Install Fuel Pump to Cylinder Head, 3 Fasteners OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 171 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.49 $0.88 $1.36 0.00% 0Pipe Assembly - Fuel, High Pressure, Pump to Rail 1170-N0101-01 1

Install High Pressure Pipe Between Fuel Rail and Pump. Run Down Two Tube Nuts

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 257 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.32 $0.58 $0.91 0.00% 0

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

1A Fuel Rail - High Pressure (w. HP Sensor) 1101-N0101-02 1 (Mini Cooper) SAC 

2A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-01 4 (Mini Cooper) SAC 3A Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) 1107-N0101-01 1 (Mini Cooper) SAC 4A Pipe Assembly - Fuel, High Pressure, Pump to Rail 1170-N0101-01 1 (Mini Cooper) SAC 

0 

5A Fuel Rail Assembly 1101-B0101-01 1 Chrysler GEMA SAC 6A Fuel Injector Assembly - Low Pressure, 4 Hole 1104-B0101-01 4 Chrysler GEMA SAC 

0 

7A Bolt - Fuel Pump (to head) 1180-N0101-02 3 S 8A Bolt - Fuel Rail (to head) 1180-N0101-01 2 S 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $104.14 $1.13 $2.04 $107.31 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (103.99) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $0.15 $1.13 $2.04 $3.33 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: No Packaging Considerations Required.Packaging Type:Part Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 12 of 12
Appendix G.1 - Subsystem 12

Exhaust Subsystem

 Case Study #0101

MAQS Worksheets

File:Exhaust Subsystem 12 033009.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-12, 1 of 6
Manifold Exhaust 1201 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Manifold - Exhaust, Dual Wall Part Number: 1201-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

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

1A Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-02 1 Cast T1 Assembly, Mark-up Applied @ Bottom. NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 141 6 1.5 2 7.760 $3.50 $43.52 $150.07 $450.21 $27.16 $1.85 $3.19 $32.20 10.00% 1B Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-01 1 Heat Treat, Pre Machine T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, MHC 129 1 3 1 0.000 $0.00 $46.52 $250.00 $750.00 $0.00 $0.36 $5.83 $6.20 0.00% 

1C Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01 1 Machining T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC 120 3 3 1.5 0.000 $0.00 $43.52 $45.00 $202.50 $0.00 $1.09 $1.69 $2.78 0.00% 

2A Manifold - Exhaust, (Chrysler) 1201-B0101-01-02 1 Cast T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Mold/Cast/Sinter Operator Sand Cast, HMC -145 6 1.5 1 -12.920 $0.35 $43.52 $150.07 $225.11 -$4.52 -$1.81 -$1.56 -$7.89 5.00% 2B Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-01-01 1 Heat Treat, Pre Machine T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, MHC -125 1 2.5 1 0.000 $0.00 $46.52 $250.00 $625.00 $0.00 -$0.37 -$5.00 -$5.37 0.00% 

2C Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-01 1 Machining T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC -120 3 3 1 0.000 $0.00 $43.52 $45.00 $135.00 $0.00 -$1.09 -$1.13 -$2.21 0.00% 

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

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

0 

0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap 

T1 or OEM Total Manufacturing Cost: $22.64 $0.03 $3.03 $25.70 $2.83 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.14 

Base Cost Impact to Vehicle: $22.64 $0.03 $3.03 $25.70 $2.97 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

Casting & Machining Assumptions:Casting: Assumption processing time increase due to part complexity and material grade is offset by reduction in material volume. Machining: 50% premium paid on machining NiResist material over base nodular cast iron. 

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 2 of 6
Manifold Exhaust 1201 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Manifold - Exhaust, Dual Wall Part Number: 1201-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Rack/Pallet Investment Amortization: $0.152 $303,191 0.00% 2,250,000 60 5.00% $380 

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

P

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

Packaging Cost Total: $0.152

 PACKAGING CALCULATIONS: MINI Packaging Type: Option #2Part Size:320x120X115Parts/Layer: 3x10Number of Layers: 7Cost $0.03/Part

 PACKAGING CALCULATIONS: GEMA Packaging Type: Option #2Part Size: 380x280x130Parts/Layer:3x4Number of Layers: 6Cost = $0.076/Part

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 3 of 6
Exh. Brkt's-Heat Shields 1275 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bracket Subassembly- Heat Shield, Top, Turbo Part Number: 1275-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

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

Bracket Subassembly- Heat Shield, Top, Turbo 1275-N0101-02 1 Install Ceramic Fiber Paper (Fiberfrax 440), crimp and form. T1 Assembly, Mark-up Applied @ Bottom. Fiberfrax 440 General Assembly Mech Assembly, MC, Base 450 1 1 1 256 $0.01 $35.51 $30.00 $30.00 $1.77 $0.08 $0.07 $1.91 0.00% 

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

Material Labor Burden TMC Scrap 

T1 or OEM Total Manufacturing Cost: $1.77 $0.08 $0.07 $1.91 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 

Base Cost Impact to Vehicle: $1.77 $0.08 $0.07 $1.91 $0.01 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

P

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

Full Quote Modification Differential Quote (Quote Summary includes 

Material Size "In^2" and Material Cost $/Inch^2.

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 4 of 6
Exhaust Sealing 1285 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bracket Subassembly - Exhaust Manifold w. Integrated Gasket Part Number: 1275-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Bracket Subassembly - Exhaust Manifold w. Integrated Gasket 1275-N0101-01 1

Upgrade from 2 to 3 layer exhaust gasket. Only considering gasket, no consideration required for heat shield mounting.

S 

0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $0.95 $0.00 $0.00 $0.95 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $0.95 $0.00 $0.00 $0.95 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 5 of 6
Engine Assembly 1200 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Vehicle Operations or Engine Assembly of Exhaust Components Part Number: 1200 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

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

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

Manifold Exhaust 1201-N0101-01 1 SAC 

Exhaust Brackets/Heat Shields 1275-N0101-02 1 SAC Exhaust Sealing 1275(85)-N0101-01 1 SAC Nut- Manifold Exhaust to Cylinder Head 1280-N0101-01 10 S Nut - Turbo to C.C. Catalytic Converter 1280-N0101-06 3 S Nut - Exhaust Manifold to Turbo 1280-N0101-07 4 (0.193-0.05) S 

0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $37.77 $0.00 $0.00 $37.77 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (35.88) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $1.89 $0.00 $0.00 $1.89 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type: No change to packaging Part Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

Cover cost of Nut-Exhaust Manifold to Turbo in Air Induction Engine Assembly Cost Sheet.

No differential labor/burden costs incurred to assembly exhaust system components. 

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 6 of 6
Appendix G.1 - Subsystem 13

Lubrication Subsystem

 Case Study #0101

MAQS Worksheets

File:13 Lubrication Subsystem 032309.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-13, 1 of 11
Oil Pump 1302 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Oil Pump Assembly Part Number: 1302-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Oil Pump Assembly 1302-N0101-01 1 Increase in Pump Capacity 15- 20% (13%PCJ & 5% Turbo) S 

0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $3.08 $0.00 $0.00 $3.08 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

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

Base Cost Impact to Vehicle: $3.08 $0.00 $0.00 $3.08 $0.02 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: No Packaging Updates RequiredPackaging Type:Part Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 2 of 11
Filter Cooler Assembly 1306 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Filter Cooler Assembly - Oil (Includes Seals) Part Number: 1306-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Oil Cooler Adapter/Base Plate Subassembly 1306-N0101-01-02-1A 1 Toggle Lock Adaptor and Base Plate Together S Not Applicable General Assembly Mech. Assembly, MC 300 1 0.000 $0.00 $35.51 $125.19 $0.00 $0.12 $0.42 $0.54 0.00% 0.00% 0.00% 0.00% 02A Oil Cooler 1306-N0101-01-02 1 Fixture and Braze Weld S Not Applicable General Assembly Mech. Assembly, MC 180 1 0.000 $0.00 $35.51 $125.19 $0.00 $0.20 $0.70 $0.89 0.00% 0.00% 0.00% 0.00% 03A Filter Cooler Assembly - Oil (Includes Seals & 

aux

1306-N0101-01 1

Final Assembly of filter/cooler assembly (Only Consider Turbo/DI Driven Costs)

S Not Applicable General Assembly Mech. Assembly, MC 240 5 0.000 $0.00 $35.51 $125.19 $0.00 $0.74 $0.52 $1.26 0.00% 0.00% 0.00% 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Housing Oil Filter Preassembled 1306-N0101-01-08 1 Casting (50% Mass Attributed to Turbo/DI oil cooler features) S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 160 1 0.900 $1.10 $43.52 $100.05 $0.99 $0.27 $0.63 $1.89 0.30% 6.00% 4.00% 0.00% 101B Housing Oil Filter Preassembled 1306-N0101-01-08 1

Machine Casting Features (Hole Attributed to Turbo/DI Only)

S Not Applicable Mold/Cast/Sinter Operator Perm. Cast, MHC 150 1 0.000 $0.00 $43.52 $150.06 $0.00 $0.29 $1.00 $1.29 0.30% 6.00% 4.00% 0.00% 10

2A Oil Cooler Adapter Plate 1306-N0101-01-02-1 1 Stamping S Aluminum-3003/4047B, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 480 0.5 0.253 $2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.78 0.30% 6.00% 4.00% 0.00% 103A Oil Cooler Base Plate 1306-N0101-01-02-2 1 Stamping S Aluminum-3003/4047B, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 480 0.5 0.253 $2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.78 0.30% 6.00% 4.00% 0.00% 104A Oil Cooler Cooling Plate stack-Lance 1306-N0101-01-02-3 5 Stamping S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 581 1 0.018 $1.65 $42.18 $100.10 $0.03 $0.07 $0.17 $0.27 0.30% 6.00% 4.00% 0.00% 105A Oil Cooler Cooling Plate stack 1306-N0101-01-02-31 7 Stamping S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1161 0.5 0.018 $1.65 $42.18 $100.10 $0.03 $0.02 $0.09 $0.13 0.30% 6.00% 4.00% 0.00% 106A Oil Cooler Top Plate 1306-N0101-01-02-4 1 Stamping S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 581 0.5 0.062 $1.65 $42.18 $100.10 $0.10 $0.04 $0.17 $0.31 0.30% 6.00% 4.00% 0.00% 10

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

Su

Ac

1A Gasket housing to block Oil 1306-N0101-01-09 1 S $2A Gasket housing to block - coolant 1306-N0101-01-10 1 S $3A Gasket Oil Cooler Odd Shape 1306-N0101-01-07 1 S $4A Gasket Oil Cooler Square 1306-N0101-01-06 1 S $5A Gasket Oil Cooler Oval 1306-N0101-01-05 1 S $6A Gasket Oil Cooler Round 1306-N0101-01-04 1 S $7A Bolt Oil Cooler to housing 1306-N0101-01-03 5 S $8A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1370-N0101-01 1 SAC $

0 $0 $0 $0 $0 $0 $0 $0 $0 $

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"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.

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 3 of 11
Filter Cooler Assembly 1306 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Filter Cooler Assembly - Oil (Includes Seals) Part Number: 1306-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

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

Ma

T1 or OEM Total Manufacturing Cost: $7.02 $2.23 $5.31 $14.57 $0.02 $0.44 $0.29 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15

(SAC) &T1 or OEM Mark-Up Values: (4.09) ----- ----- ----- $0.08 $1.00 $0.92 $0.38 $

Base Cost Impact to Vehicle: $2.93 $2.23 $5.31 $10.48 $0.10 $1.44 $1.21 $0.38 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.068 $136,778 0.00% 2,250,000 60 5.00% $200 684 84 

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

O

Pal

Expendable Packaging in Piece Cost: $0.10 $1.00 8 $0.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.164

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 4 of 11
Tube Ass'y Turbo to Block 1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly - Oil, Turbo to Engine Block Part Number: 1370 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-02 1

Assemble End Fittings and Orings onto Tube and Crimp in Place. Pressure Test

S Not Applicable General Assembly Mech. Assembly, LC 240 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.30 $0.42 $0.71 0.00% 0.00% 0.00% 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-2 1 Tube Bending S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC360 0.5 0.210 $0.62 $42.18 $100.12 $0.13 $0.06 $0.28 $0.47 0.00% 0.00% 0.00% 0.00% 01B Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-1 1 Flare Tube Ends S Not Applicable Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC240 1 0.210 $0.00 $42.18 $100.12 $0.00 $0.18 $0.42 $0.59 0.00% 0.00% 0.00% 0.00% 0

1C Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-3 1 Plate S General Underhood PlatingPlating/Coating Operator Plate/Finish, SMS, MHC 720 1 0.001 $15.00 $55.17 $125.17 $0.02 $0.08 $0.17 $0.27 0.30% 6.00% 4.00% 0.00% 10

2A Fitting Tube End 1370-N0101-02-4 2 Forge Blank S MC-Steel-1018, Bar Forging Operator Cold Forge, LMC 900 0.5 0.165 $0.55 $38.52 $100.09 $0.09 $0.02 $0.11 $0.22 0.00% 0.00% 0.00% 0.00% 02B Fitting Tube End 1370-N0101-02-4 2 Machine S Not Applicable CNC Operator CNC Milling, SMS, LC 360 0.5 0.000 $0.00 $35.70 $100.15 $0.00 $0.05 $0.28 $0.33 0.00% 0.00% 0.00% 0.00% 0

2C Fitting Tube End 1370-N0101-02-4 2 Plate S General Underhood PlatingPlating/Coating Operator Plate/Finish, SMS, MHC 1800 1 0.001 $15.00 $55.17 $125.17 $0.02 $0.03 $0.07 $0.12 0.30% 6.00% 4.00% 0.00% 10

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

Su

Ac

1A O-ring - Tube Fitting 1370-N0101-02-3 1 S $

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $0.42 $0.81 $2.20 $3.43 $0.00 $0.03 $0.02 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.21 $0.14 $0.00 $

Base Cost Impact to Vehicle: $0.42 $0.81 $2.20 $3.43 $0.01 $0.24 $0.16 $0.00 $

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"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.

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 5 of 11
Tube Ass'y Turbo to Block 1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly - Oil, Turbo to Engine Block Part Number: 1370 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.055 $110,206 0.00% 2,250,000 60 5.00% $4,420 25 2304 

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

O

Pal

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

Packaging Cost Total: $0.055

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 6 of 11
Tube Ass'y Oil Cool-Turbo1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger Part Number: 1370-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

1A Fitting Hose Oil Cooler to Turbo 1306-N0101-01-11-2 1 Braze weld Tube Fitting to Bracket Mount S Not Applicable General Assembly Mech. Assembly, LC 257 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.14 $0.39 $0.53 0.00% 0.00% 0.00% 0.00% 1B Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1306-N0101-01-11 (1370-N0101-01) 1 Crimp End Fitting to Hose and Add Protective Heat Shield, Oring and Clamp S Not Applicable General Assembly Mech. Assembly, LC 240 3 0.000 $0.00 $35.51 $100.19 $0.00 $0.44 $0.42 $0.86 0.00% 0.00% 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Hose Oil Cooler to Turbo 1306-N0101-01-11-1 1 Extrude & Shape Hose S

SBR-Fiber Rein. W. Outer Wrap, Extruded

Extruding/Drawing Operator Comp./Ext. Mold, LMC 545 1.5 0.007 $2.05 $54.35 $100.04 $0.01 $0.15 $0.18 $0.35 0.00% 0.00% 0.00% 0.00% 

2A Tube Fitting end 1306-N0101-01-11-2-1 1 Machining S LC-Steel-1215, Tubing CNC Operator CNC Turning, LMC 200 0.25 0.150 $0.62 $35.70 $100.00 $0.09 $0.04 $0.50 $0.64 0.00% 0.00% 0.00% 0.00% 3A Bracket Tube Fitting end attach 1306-N0101-01-11-2-1-1 1 Fine blank, LMC S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC 1000 0.5 0.207 $0.45 $42.18 $100.13 $0.09 $0.02 $0.10 $0.21 0.30% 6.00% 4.00% 0.00% 1

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

S

A

1A Collar Tube fitting attachment 1306-N0101-01-11-2-1-2 1 S 2A Heat Shield, Hose 1306-N0101-01-11-2 1 S 3A Hose Clamp 1306-N0101-01-11-3 1 S 4A O-ring 1306-N0101-01-11-4 1 S 

0 0 0 0 0 0 0 0 0 0 

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

T1 or OEM Total Manufacturing Cost: $1.27 $0.80 $1.59 $3.66 $0.00 $0.01 $0.01 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 1

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.22 $0.15 $0.00 

Base Cost Impact to Vehicle: $1.27 $0.80 $1.59 $3.66 $0.01 $0.23 $0.16 $0.00 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"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.

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 7 of 11
Tube Ass'y Oil Cool-Turbo1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger Part Number: 1370-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

S

Cu

I

I

Re

Rack/Pallet Investment Amortization: $0.026 $51,950 0.00% 2,250,000 60 5.00% $5,860 9 6480 

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

Oth

P

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

Packaging Cost Total: $0.026

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 8 of 11
Oil - Synthetic 1399 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Oil - Synthetic Part Number: 1399-N0101-08 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

Su

Ac

1A OIL - ENGINE 0W-40 ILSAC GF3 MS-10725 NA 1 S $

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

Ma

T1 or OEM Total Manufacturing Cost: $4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

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

Base Cost Impact to Vehicle: $4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"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.

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 9 of 11
Engine Assembly 1300 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Additional or Revised Lubrication Components to Engine Part Number: 1300-N0101-00 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

1A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-02 1 Install Tube Assembly to Engine OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 2A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1306-N0101-01-11 (1370-N0101-01) 1 Install Hose to Turbo Assembly, Run Down Bolt OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 240 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.35 $0.63 $0.97 0.00% 0.00% 0.00% 0.00% 3A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-01 1 Install Filter Cooler Assembly and Run Down 4 Bolts OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 180 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.46 $0.83 $1.30 0.00% 0.00% 0.00% 0.00% 

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

Ac

1A Bolt - Tube Assembly , Oil, Turbo Outlet & Block I 1380-N0101-06 2 Banjo Bolts S 2A Washer - Bolt - Tube Assembly , Oil, Turbo Outlet 1380-N0101-09 4 Banjo Washers S 3A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-02 1 SAC 4A Bolt hose oil cooler to turbo 1306-N0101-01-12 1 S 5A Bolt - Filter Cooler Assembly 1380-N0101-08 4 S 6A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-01 1 SAC 7A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1370-N0101-01 1 SAC 

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

T1 or OEM Total Manufacturing Cost: $22.64 $1.46 $2.63 $26.72 $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: (21.71) ----- ----- ----- $0.00 $0.00 $0.00 $0.00 

Base Cost Impact to Vehicle: $0.93 $1.46 $2.63 $5.02 $0.00 $0.00 $0.00 $0.00 

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Cu

Re

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

Ot

P

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COST

10

9,574

47

450,000

1

450,000

"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.

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 10 of 11
Engine Assembly 1300 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Additional or Revised Lubrication Components to Engine Part Number: 1300-N0101-00 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COST

10

9,574

47

450,000

1

450,000

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 11 of 11
Appendix G.1 - Subsystem 14

Cooling Subsystem

 Case Study #0101

MAQS Worksheets

File:14 Cooling System 033109.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-14, 1 of 9
Pump-Aux. Coolant 1401 R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Pump- Auxiliary Coolant, Electric Part Number: 1401-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Charge Impeller Assembly 1401-N0101-02-3-1 1 Magnetize Impeller Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 240 1 1 1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.15 $0.13 $0.27 0.00% 02A Pump-Auxiliary Coolant Final Assembly 1401-N0101-02 1 Final Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 240 2 1 9 0.000 $0.00 $35.51 $30.00 $270.00 $0.00 $0.30 $1.13 $1.42 0.00% 0

INTENTIONAL BLANK SPACE 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

3A Pump-Auxiliary Coolant, Electric Subassembly 1401- N0101-00 (New P/N ) 1 Assemble pump to bracket and hoses to pump. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 4 1 4 0.000 $0.00 $35.51 $15.00 $60.00 $0.00 $0.71 $0.30 $1.01 0.00% 0

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

Purchase Part - High Impact Item (Full Cost Mapping)

1A Motor Housing Assembly 1401-N0101-02-1-1 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 360 0.5 1 2 0.110 $6.02 $43.52 $150.01 $300.02 $0.66 $0.06 $0.83 $1.56 0.00% 02A End Cap Motor close out 1401-N0101-02-1-2 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 769 0.5 1 1 0.025 $3.86 $43.52 $150.01 $150.01 $0.10 $0.03 $0.20 $0.32 0.00% 03A Housing Impellor Cavity 1401-N0101-02-2-1 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 626 0.5 1 1 0.094 $3.86 $43.52 $150.01 $150.01 $0.36 $0.03 $0.24 $0.64 0.00% 04A Impellor Water Pump 1401-N0101-02-3-1-1 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 333 0.5 1 1.5 0.100 $6.02 $43.52 $150.01 $225.02 $0.60 $0.07 $0.68 $1.34 0.00% 0

INTENTIONAL BLANK SPACE 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

1A Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y 1475-N0101-01-03 1 Progressive Die Blank T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 1 1 0.808 $0.45 $42.18 $100.10 $100.10 $0.36 $0.04 $0.17 $0.57 0.00% 01B Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y 1475-N0101-01-02 1 Stage Tooling (3 Stage) T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 240 1 1 1 0.000 $0.00 $42.18 $100.10 $100.10 $0.00 $0.18 $0.42 $0.59 0.00% 0

1C Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y 1475-N0101-01-01 1 Apply Coating T2/T3 Plate/Finish Mech., SSLC Powder Coat Plating/Coating Operator Plate/Finish, SMS, LMC 720 1 1 1 0.010 $20.00 $55.17 $100.17 $100.17 $0.20 $0.08 $0.14 $0.42 0.30% 6

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

1A Terminals 1401-N0101-02-71 1 Terminals Tin Plate S 

2A O-ring - Motor Housing to Impeller Housing 1401-N0101-02-72 1 Silicone S 3A AlNiCo Magnets 1401-N0101-02-73 4 (Uncharged, Approx 10x20x2.5) S 4A Motor Winding Assembly 1401-N0101-02-1-1-3 1 S 5A PCB Motor Control Assembly 1401-N0101-02-1-1-2 1 S 6A E-Clip 1401-N0101-02-5 1 S 7A Heat Sink 1401-N0101-02-6 1 S 8A Screw Impellor cavity to motor housing 1401-N0101-02-2-2 4 S 9A Bolt pump to bracket 1401-N0101-02-02 3 S 

10A Wire Harness Retention Clips NA 2 Required for O2 Sensor, Thus No Cost Impact. S 11A Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary Pump 1470-N0101-04 1 SAC 12A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03 1 SAC 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $19.78 $1.63 $4.22 $25.63 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

(SAC) &T1 or OEM Mark-Up Values: (5.88) ----- ----- ----- $0.18 

Base Cost Impact to Vehicle: $13.90 $1.63 $4.22 $19.75 $0.18 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 2 of 9
Pump-Aux. Coolant 1401 R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Pump- Auxiliary Coolant, Electric Part Number: 1401-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.059 $118,203 0.00% 2,250,000 60 5.00% $500 

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

O

Pa

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

Packaging Cost Total: $0.059

 PACKAGING CALCULATIONS: Packaging Type: Option 1 w. Expendable DividersPart Size: 340X130X90Parts/Layer:3X9Number of Layers: 9

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 3 of 9
Hose,Oil Cool. - Aux Pump 1470D Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Locati

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Locati

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Meth

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specificati

Component Description: Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary Pump Part Number: 1470-N0101-04 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

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

1A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-1 1 Extrude & Shape Hose S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 273 1.5 0.127 $1.85 $54.35 $100.04 $0.23 $0.30 $0.37 $0.90 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.90 $0.2A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-1 1 Assemble Sheathing and Glue Clamps S Purchased Parts General Assembly Mech Assembly, LC, Base 240 2 $0.62 $1.00 $35.51 $15.00 $0.62 $0.30 $0.06 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purch

Price 

End I

1A Sheath Hose Protection (Aux-Filter) 1470-N0101-04-2 1 Nylon B2B $0.00 $0.28 $0.28 $0.

2A Hose Clamp 1470-N0101-03-1 2 Steel- Zinc Phosphate B2B $0.00 $0.17 $0.34 $0.

0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.

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

T1 or OEM Total Manufacturing Cost: $0.85 $0.59 $0.43 $1.88 $0.00 $0.00 $0.00 $0.00 $0.00 $1.

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.11 $0.08 $0.00 $0.19

Base Cost Impact to Vehicle: $0.85 $0.59 $0.43 $1.88 $0.01 $0.11 $0.08 $0.00 $0.19 $2.

Packaging Cost: $0.

Net Cost Impact to Vehicle: $2.

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 57447 1 6 57447

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

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COST

10

9,574

47

450,000

1

450,000

Packaging Pump, No 

"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.

3

1

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 4 of 9
Hose Ass'y-Turbo-Aux Pump 1470C Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Auxiliary Pump to Turbo Part Number: 1470-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Fitting Hose End 1306-N0101-01-11-5 1 Cold Headed Tubing S LC-Steel-1215, Tubing Forging Operator Cold Forge, LMC 720 0.5 0.092 $0.62 $38.52 $100.09 $0.06 $0.03 $0.14 $0.22 0.00% 0.00% 0.00% 0.00% 02A Fitting Tube End 1370-N0101-02-4 1 CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC 240 0.5 0.270 $0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.76 0.00% 0.00% 0.00% 0.00% 03A Tube 1306-N0101-01-11-5-2 1 Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 360 0.5 0.030 $0.62 $42.18 $100.12 $0.02 $0.06 $0.28 $0.36 0.00% 0.00% 0.00% 0.00% 04A Tube Assembly - Banjo Joint for Turbo 1470-N0101-03-03 1 Assemble, Braze and Plate S Not Applicable General Assembly Mech. Assembly, LC 257 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.28 $0.39 $0.67 0.00% 0.00% 0.00% 0.00% 05A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-02 1 Extrude & Shape Hose S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 581 1.5 0.091 $1.85 $54.35 $100.04 $0.17 $0.14 $0.17 $0.48 0.00% 0.00% 0.00% 0.00% 06A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-01 1 Overmold Banjo Tube to Hose S Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 360 1 0.007 $1.74 $43.52 $100.01 $0.01 $0.12 $0.28 $0.41 0.00% 0.00% 0.00% 0.00% 07A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03 1 Assemble Sheathing and Glue Clamp S Purchased Parts General Assembly Mech Assembly, LC, Base 200 1 $0.30 $1.00 $35.51 $15.00 $0.30 $0.18 $0.08 $0.55 0.00% 0.00% 0.00% 0.00% 0

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0

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

Su

Ac

1A Hose Clamp 1470-N0101-03-1 1 Steel- Zinc Phosphate B3C $2A Sheath Hose protection (Turbo) 1470-N0101-03-2 1 B3C $

$

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $0.72 $0.87 $1.85 $3.45 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.21 $0.14 $0.00 $

Base Cost Impact to Vehicle: $0.72 $0.87 $1.85 $3.45 $0.01 $0.21 $0.14 $0.00 $

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"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.

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 5 of 9
Hose Ass'y-Turbo-Aux Pump 1470C Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Auxiliary Pump to Turbo Part Number: 1470-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 6 of 9
Hose Ass'y Turbo-Thermo, 1470 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve Part Number: 1470-N0101-02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

1A Tube Assembly Prefabricated 1470-N0101-02-04-01 1 Assemble, Braze S Not Applicable General Assembly Mech Assembly, HC, Base 240 1 0.000 $0.00 $35.51 $45.00 $0.00 $0.15 $0.19 $0.34 0.00% 0.00% 0.00% 0.00% 2A Tube Assembly Prefabricated 1470-N0101-02-04-02 1 Projection Weld Brkt S Not Applicable General Assembly Mech Assembly, LC, Base 240 1 0.000 $0.00 $35.51 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 3A Tube Assembly Prefabricated 1470-N0101-02-04-02 1 Plating S General Underhood Plating Plating/Coating Operator Plate/Finish, MLS, LMC 720 1 0.001 $15.00 $55.17 $150.17 $0.02 $0.08 $0.21 $0.30 0.00% 0.00% 0.00% 0.00% 4A Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 1470-N0101-02 1 Assemble SBR Tube with two hose clamps S Not Applicable General Assembly Mech Assembly, LC, Base 240 2 0.000 $0.00 $35.51 $15.00 $0.00 $0.30 $0.06 $0.36 0.00% 0.00% 0.00% 0.00% 

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Fitting Tube End 1370-N0101-02-4 1 CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC 240 0.5 0.270 $0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.76 0.00% 0.00% 0.00% 0.00% 2A Bracket Tube Attachment 1470-N0101-02-4-4 1 Stamping S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 0.233 $0.45 $42.18 $100.10 $0.10 $0.04 $0.17 $0.31 0.00% 0.00% 0.00% 0.00% 3A Preformed Tube 10mm OD 1470-N0101-02-4-1 1 Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 360 0.5 0.150 $0.62 $42.18 $100.12 $0.09 $0.06 $0.28 $0.43 0.00% 0.00% 0.00% 0.00% 4A Preformed Tube 14mm OD 1470-N0101-02-4-2 1 Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 240 1 0.060 $0.62 $42.18 $100.12 $0.04 $0.18 $0.42 $0.63 0.00% 0.00% 0.00% 0.00% 5A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-1 1 Extrude & Shape Hose S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 933 1.5 0.055 $1.85 $54.35 $100.04 $0.10 $0.09 $0.11 $0.30 0.00% 0.00% 0.00% 0.00% 

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

S

A

1A Hose Clamp small ID 1470-N0101-02-2 1 S 2A Hose Clamp large ID 1470-N0101-02-3 1 S 

0 0 0 0 0 0 0 0 0 0 0 0 

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

T1 or OEM Total Manufacturing Cost: $1.02 $1.10 $2.01 $4.13 $0.00 $0.00 $0.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.03% 6.00% 4.00% 0.00% 1

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.25 $0.17 $0.00 

Base Cost Impact to Vehicle: $1.02 $1.10 $2.01 $4.13 $0.00 $0.25 $0.17 $0.00 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"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.

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 7 of 9
Hose Ass'y Turbo-Thermo, 1470 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve Part Number: 1470-N0101-02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

S

Cu

I

I

Re

Rack/Pallet Investment Amortization: $0.015 $30,395 0.00% 2,250,000 60 5.00% $200 152 378 

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

Oth

P

Expendable Packaging in Piece Cost: $0.03 $1.00 10 $3.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.042

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 8 of 9
Engine Assembly 1400 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Additional or Revised Assembly Components to Engine Part Number: 1400-N0101-00 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Assembly Pump-Aux. Coolant Subassembly 1401-N0101-02+ Subs 1

Mount Auxiliary Pump to Oil 

Cooler/Filter (2 Screws), Make Electrical Connection Constrain wire in Clips

OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 0

2A Hose Assembly, Turbo -Aux Pump and Hose Ass'y- Turbo - Thermostat Valve 1470-N0101-02/03 1 Install and run Banjo bolt (x2) @ turbo. OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 03A Hose, Oil Cooler to Aux Pump and Hose Ass'y Turbo Thermostat Valve to Thermostat Valve 1470-N0101-02/04 1 Press on Tubes and release Hose Clamps OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 04A Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 1470-N0101-02 0 Run fastener to secure Hose Assembly Bracket to Engine OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 300 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.28 $0.50 $0.78 0.00% 0.00% 0.00% 0.00% 0

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

Su

Ac

1A Bolt-Hose, coolant Inlet and Outlet @ Turbo 1480-N0101-06 2 Banjo Bolts S $2A Washer banjo Bolt-Hose, coolant Inlet and Outlet @1480-N0101-13 4 Banjo Washers S $3A Bolt-Hose Bracket, coolant Inlet and Outlet @ Turbo 1480-N0101-14 1 S $4A Bolt Aux pump bracket to oil cooler 1480-N0101-07 3 S $5A Pump- Auxiliary Coolant, Electric 1401-N0101-02 1 SAC $26A Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 1470-N0101-02 1 SAC $

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

Ma

T1 or OEM Total Manufacturing Cost: $30.23 $1.94 $3.50 $35.68 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (29.49) ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $

Base Cost Impact to Vehicle: $0.74 $1.94 $3.50 $6.19 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"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.

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 9 of 9
Appendix G.1 - Subsystem 15

Air Induction Charging Subsystem

 Case Study #0101

MAQS Worksheets

File:15 Air Induction Charging System 040109A.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-15, 1 of 16
Turbo Assembly 1501 Rev 5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Turbo Charging Assembly Part Number: 1501-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) 

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

1A Block Turbo shaft support - cooling & lub 1201-N0101-01-10 1 Subassembly Center Support Block T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 177 4 1 8 0.000 $0.00 $35.51 $30.00 $240.00 $0.00 $0.80 $1.35 $2.15 0.00% 0.00% 2A Housing Turbo Exhaust 1201-N0101-01-09 1 Subassembly Exhaust Housing T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 180 2 1 3 0.000 $0.00 $35.51 $15.00 $45.00 $0.00 $0.39 $0.25 $0.64 0.00% 0.00% 3A Final Assembly Line 1501-N0101-01 1 Final Product Assembly & Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 180 11 1 13 0.000 $0.00 $35.51 $15.00 $195.00 $0.00 $2.17 $1.08 $3.25 0.00% 0.00% 4A Turbine Shaft Assembly - Welded 1201-N0101-01-01-24-01 1

Electron Beam Weld Turbine Impeller to Shaft and Grind Profile

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 180 1 1 2 0.000 $0.00 $35.51 $30.00 $60.00 $0.00 $0.20 $0.33 $0.53 0.00% 0.00% 

5A Turbo Assembly Center Housing Rotating Assembly (CHRA) Balancing 1201-N0101-01-01-24 1 High Speed Dynamic Balancing T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 180 4.5 3 1 0.000 $0.00 $35.51 $45.00 $135.00 $0.00 $0.89 $0.75 $1.64 10.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Housing Turbo Intake Casting 1201-N0101-01-07-01-2 1 Cast Intake Housing T2/T3 Sand Cast, MSMC Aluminum-A319-T5, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 120 6 1 1 2.200 $1.15 $43.52 $150.07 $150.07 $2.53 $2.18 $1.25 $5.96 5.00% 6.50% 1B Housing Turbo Intake Casting 1201-N0101-01-07-01-1 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 125 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.37 $0.80 $1.17 0.50% 6.50% 

1C Housing Turbo Intake Casting 1201-N0101-01-07-01 1 Machine Intake Housing T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 119 3 7 1 0.000 $0.00 $35.70 $45.00 $315.00 $0.00 $0.90 $2.64 $3.53 0.50% 6.50% 

2A Block Center Bearing Support 1201-N0101-01-30-02 1 Sand Casting T2/T3 Sand Cast, MSMC SiMo Ductile Iron, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 160 9 1 1 3.500 $0.60 $43.52 $150.07 $150.07 $2.10 $2.45 $0.94 $5.49 5.00% 6.50% 2B Block Center Bearing Support 1201-N0101-01-30-01 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 167 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.28 $0.60 $0.88 0.50% 6.50% 

2C Block Center Bearing Support 1201-N0101-01-30 1 Critical Faces Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 122 4 8 1 0.000 $0.00 $35.70 $45.00 $360.00 $0.00 $1.18 $2.96 $4.14 0.50% 6.50% 

3A Housing Turbo Exhaust 1201-N0101-01-09-01-02 1 Sand Casting T2/T3 Sand Cast, MSMC NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 120 6 1 1 6.890 $3.50 $43.52 $150.07 $150.07 $24.12 $2.18 $1.25 $27.54 5.00% 6.50% 3B Housing Turbo Intake Casting 1201-N0101-01-09-01-01 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 114 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.41 $0.88 $1.28 0.50% 6.50% 

3C Housing Turbo Exhaust 1201-N0101-01-09-01 1 Machine Casting T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC, PREM. 114 3 6 1 0.000 $0.00 $35.70 $55.00 $330.00 $0.00 $0.94 $2.90 $3.84 0.50% 6.50% 

4A Support Plate intake side 1201-N0101-01-26-02 1 Diecasting T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 275 1 1 1 0.421 $1.10 $43.52 $100.05 $100.05 $0.46 $0.16 $0.36 $0.99 5.00% 6.00% 4B Support Plate intake side 1201-N0101-01-26-01 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 267 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.17 $0.38 $0.55 0.50% 6.50% 

4C Support Plate intake side 1201-N0101-01-26 1 Machine Casting T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, MC 129 1 2 1 0.000 $0.00 $35.70 $45.00 $90.00 $0.00 $0.28 $0.70 $0.98 0.30% 6.00% 

5A Heat Shield Exhaust shaft seal 1201-N0101-01-29 1 Stamp T2/T3 Stamp/Form, SSLC Inconel-713C, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 621 0.5 1 1 0.029 $6.00 $42.18 $100.10 $100.10 $0.17 $0.03 $0.16 $0.37 0.30% 6.00% 6A Anti-rotate plate - bushing 1201-N0101-01-34 1 Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.5 1 1 0.005 $0.65 $42.18 $100.10 $100.10 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 7A Plate Brass Oil Diverter 1201-N0101-01-19-1 1 Stamp Part T2/T3 Stamp/Form, SSLC Bronze-89320, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 679 0.5 1 1 0.027 $2.56 $42.18 $100.10 $100.10 $0.07 $0.03 $0.15 $0.25 0.30% 6.00% 7B Plate Brass Oil Diverter 1201-N0101-01-19 1 Machine Oil Pass Through T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC 257 0.25 1 2 0.000 $0.00 $35.70 $25.00 $50.00 $0.00 $0.03 $0.19 $0.23 0.50% 6.50% 8A Bushing - Turbine Shaft 1201-N0101-01-32 1 Screw Machine T2/T3 CNC Turning, MSMC Bronze-89320, Bar CNC Operator S-CNC Turning, HC 117 1 2.5 1 0.070 $2.56 $35.70 $85.00 $212.50 $0.18 $0.31 $1.82 $2.30 0.50% 6.50% 9A Seal Carrier support plate mount 1201-N0101-01-27-01 1 Screw Machine T2/T3 CNC Turning, MSMC A-Steel-4140, Bar CNC Operator S-CNC Turning, LC 160 1 2 1 0.040 $0.78 $35.70 $35.00 $70.00 $0.03 $0.22 $0.44 $0.69 0.50% 6.50% 

10A Valve Exhaust Dump 1201-N0101-01-09-01-05-02 1 Investment Cast T2/T3 Invest. Cast, LSHC Nickel Alloy Gen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 120 7 1 1 0.150 $5.00 $43.52 $150.08 $150.08 $0.75 $2.54 $1.25 $4.54 5.00% 7.00% 10B Valve Exhaust Dump 1201-N0101-01-09-01-05-01 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 118 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.39 $0.84 $1.24 0.50% 6.50% 

10C Valve Exhaust Dump 1201-N0101-01-09-01-05 1 Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM. 180 0.5 1 1 0.000 $0.00 $35.70 $35.00 $35.00 $0.00 $0.10 $0.19 $0.29 0.50% 6.50% 

11A Arm - Valve to Shaft 1201-N0101-01-09-01-06-02 1 Investment Cast T2/T3 Invest. Cast, LSHC Nickel Alloy Gen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 120 7 1 1 0.153 $5.00 $43.52 $150.08 $150.08 $0.77 $2.54 $1.25 $4.55 5.00% 7.00% 11B Arm - Valve to Shaft 1201-N0101-01-09-01-06-01 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 118 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.39 $0.84 $1.24 0.50% 6.50% 

11C Arm - Valve to Shaft 1201-N0101-01-09-01-06 1 Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM. 120 0.5 1 1 0.000 $0.00 $35.70 $35.00 $35.00 $0.00 $0.15 $0.29 $0.44 0.50% 6.50% 

12A Block control rod attachment 1201-N0101-01-09-01-10 1 Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 960 3 1 1 0.042 $2.40 $43.52 $100.06 $100.06 $0.10 $0.14 $0.10 $0.34 5.00% 6.00% 12B Block control rod attachment 1201-N0101-01-09-01-10 1 Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM. 200 0.5 1 1 0.000 $0.00 $35.70 $35.00 $35.00 $0.00 $0.09 $0.18 $0.26 0.50% 6.50% 13A Arm Dump Valve Control 1201-N0101-01-09-01-08 1 Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 960 3 1 1 0.050 $2.40 $43.52 $100.06 $100.06 $0.12 $0.14 $0.10 $0.36 5.00% 6.00% 14A Impeller Intake 1201-N0101-01-16-03 1 Rubber/Plaster Mold T2/T3 Invest. Cast, LSHC Aluminum-356-T6, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 180 5 1.25 1 0.064 $1.20 $43.52 $150.08 $187.60 $0.08 $1.21 $1.04 $2.33 25.00% 7.00% 14B Impeller Intake 1201-N0101-01-16-02 1 T6 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 174 1 1.5 1 0.000 $0.00 $46.52 $100.00 $150.00 $0.00 $0.27 $0.86 $1.13 20.00% 6.50% 

14C Impeller Intake 1201-N0101-01-16-01 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 164 1 2.5 1 0.000 $0.00 $35.70 $45.00 $112.50 $0.00 $0.22 $0.69 $0.91 20.00% 6.50% 14D Impeller Intake 1201-N0101-01-16 1 2 Plane Dynamic Balance T2/T3 CNC Turning, MSMC Not Applicable Precision Assembly Balancing, SMS, MHC 180 4.5 3 1 0.000 $0.00 $25.74 $45.00 $135.00 $0.00 $0.64 $0.75 $1.39 20.00% 6.50% 

15A Turbine Wheel 1201-N0101-01-01-24-05 1 Investment Cast T2/T3 Invest. Cast, LSHC Inconel-713, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 180 9 1.5 1 0.075 $6.00 $43.52 $150.08 $225.12 $0.45 $2.18 $1.25 $3.88 25.00% 7.00% 15B Turbine Wheel 1201-N0101-01-01-24-04 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 178 1 1.5 1 0.000 $0.00 $46.52 $100.00 $150.00 $0.00 $0.26 $0.84 $1.11 20.00% 6.50% 

15C Turbine Wheel 1201-N0101-01-01-24-03 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 180 0.5 1 1 0.000 $0.00 $35.70 $45.00 $45.00 $0.00 $0.10 $0.25 $0.35 20.00% 6.50% 15D Turbine Wheel 1201-N0101-01-01-24-02 1 2 Plane Dynamic Balance T2/T3 CNC Turning, MSMC Not Applicable Precision Assembly Balancing, SMS, MHC 180 4.5 3 1 0.000 $0.00 $25.74 $45.00 $135.00 $0.00 $0.64 $0.75 $1.39 20.00% 6.50% 

16A Turnbine Shaft 1201-N0101-01-01-24-03-01 1 Machine & Grind Shaft T2/T3 CNC Turning, MSMC A-Steel-4140, Bar CNC Operator S-CNC Turning, MC 176 1 2.5 1 0.255 $0.78 $35.70 $55.00 $137.50 $0.20 $0.20 $0.78 $1.18 10.00% 6.50% 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Quote Differential Quote (Quote Summary includes 

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APPENDIX G.1-15, 2 of 16
Turbo Assembly 1501 Rev 5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Turbo Charging Assembly Part Number: 1501-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Quote Differential Quote (Quote Summary includes 

16B Turnbine Shaft 1201-N0101-01-01-24-03 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 250 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.40 $0.59 10.00% 6.50% 

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

1A Seal Shaft exhaust end 1201-N0101-01-25 1 (M2 Tool Steel & Inconel) S 

2A Plug Threaded 1201-N0101-01-30-03 2 S 3A Sleeve Shaft Bushing 1201-N0101-01-30-02 1 S 4A Snap Ring - Bearing retainer 1201-N0101-01-31 1 S 

5a C-Clip - Bushing Retainer 1201-N0101-01-33 1 S 

6A O-Ring Inner ID of support plate to block 1201-N0101-01-21 1 S 7A Spacer Oil Diverter Plates 1201-N0101-01-20 1 S 8A Seal - Shaft Support Plate to seal carrier 1201-N0101-01-28 1 S 9A Nut turbine Shaft 1201-N0101-01-15 1 S 

10A O-Ring Intake Housing to block seal 1201-N0101-01-14 1 S 11A Bolt Intake Housing to Shaft Housing 1201-N0101-01-04 4 S 12A Pin Housing to Center Block Locating 1201-N0101-01-09-01-13 1 S 13A Bushing Dump Valve Shaft 1201-N0101-01-09-01-09 1 (Specialized Alloy or Nitrided) S 14A Washer - Valve Retainer 1201-N0101-01-09-01-07 1 Stainless S 15A Washer Block retainer 1201-N0101-01-09-01-11 1 Steel S 16A Stud Turbo to Exhaust Manifold 1201-N0101-01-11 4 Stainless (A286) S 17A Stud - Catalytic Coverter 1280-N0101-07 3 Stainless (A286) S 18A Clamp Exhaust housing to shaft block 1201-N0101-01-08 1 Stainless S 19A Nut Saddle Clamp 1201-N0101-01-13 1 Stainless S 20A Solenoid Intake Bypass 1201-N0101-01-05 1 S 21A Gasket Intake Housing Solenoid 1201-N0101-01-12 1 S 22A Bolt Solenoid to Intake Housing 1201-N0101-01-06 3 S 23A Diaphram Exhaust dump valve 1201-N0101-01-01 1 S 24A Nut Exhaust Diaphram Shaft 1201-N0101-01-02 2 S 25A Nut Diaphram to Intake Housing 1201-N0101-01-03 2 S 26A Gasket - Turbo Inlet to Exhaust Manifold 1285-N0101-01 1 S 27A Nut - Turbo to exhaust Manifold 1280-N0101-10 4 S 28A Tag ID 1201-N0101-01-07-02 1 S 29A Rivet ID Tag 1201-N0101-01-07-03 1 S 

0 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $49.30 $26.79 $33.75 $109.84 $5.45 $5.38 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.89 $8.87 

Base Cost Impact to Vehicle: $49.30 $26.79 $33.75 $109.84 $6.34 $14.2

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/ 

Racks Required

Rack/Pallet Investment Amortization: $0.108 $215,426 0.00% 2,250,000 60 5.00% $300 718 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.108

 PACKAGING CALCULATIONS: Packaging Type: Option #2Part Size: 300x200X190Parts/Layer: 4x5Number of Layers: 4

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APPENDIX G.1-15, 3 of 16
Cooler Assembly 1505 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loc

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loc

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specific

Component Description: Cooler Assembly - Charged Air Part Number: 1505-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

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

1B Tube with cooling fins 1505-N0101-01-1-1 5

Insert Cooling Fins, Laser weld seem on Tube, Pressure Test.

S Not Applicable General Assembly Mech. Assembly, MC 566 2 0.000 $0.00 $35.51 $125.19 $0.00 $0.13 $0.22 $0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.35 

2C Cooler Assembly - Charged Air Heat Exchanger 1505-N0101-01-01-02 1

Assemble Tube Assemblies, 

Outer Fins, Top/Bottom Plates and Header Plates, Gasket & End Caps

S Not Applicable General Assembly Mech. Assembly, MC 116 5 0.000 $0.00 $35.51 $125.19 $0.00 $1.53 $1.08 $2.61 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.61 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube 1505-N0101-01-1-2 5 Pre-Form & Cut to Length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 514 0.5 0.320 $1.65 $42.18 $125.10 $0.53 $0.04 $0.24 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 2A Cooling Fins Inside Tube 1505-N0101-01-1-3-01 5 Form and Cut to Length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 720 0.5 0.100 $1.65 $42.18 $125.10 $0.17 $0.03 $0.17 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 3A Top/Bottom Plates 1505-N0101-01-1-4 2 Form and Cut to Length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 720 0.5 0.110 $1.65 $42.18 $125.10 $0.18 $0.03 $0.17 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 4A Cooling Fins Outer 1505-N0101-01-1-5--01 6 Lance, Form, Cut to length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 720 0.5 0.140 $1.65 $42.18 $125.10 $0.23 $0.03 $0.17 $0.43 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.43 4B Header Plate 1505-N0101-01-1-6-01 2 Pierce and Form S

Aluminum3003/4047B, Cladding

Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 529 0.25 0.130 $2.10 $42.18 $125.10 $0.27 $0.02 $0.24 $0.53 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.53 

5A End Cap R Cooler Assembly - Charged Air Heat Exchange 1505-N0101-01-2 1 Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 655 0.5 0.254 $1.54 $43.52 $100.01 $0.39 $0.03 $0.15 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.58 5B End Cap L Cooler Assembly - Charged Air Heat Exchange 1505-N0101-01-3 1 Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 643 0.5 0.299 $1.54 $43.52 $100.01 $0.46 $0.03 $0.16 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.65 

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

Supplier 

Account 

Cost

Purchase Price/ 

Unit

Purchase Price 

Net, PIA

Pu

Ne

1A Gasket End Cap 1505-N0101-01-4 2 S $0.00 $0.15 $0.00 

0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 

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

T1 or OEM Total Manufacturing Cost: $6.91 $2.85 $6.44 $16.20 $0.00 $0.00 $0.00 $0.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.00% 6.00% 2.00% 14.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.08 $0.97 $0.97 $0.32 $2.35

Base Cost Impact to Vehicle: $6.91 $2.85 $6.44 $16.20 $0.08 $0.97 $0.97 $0.32 $2.35 

Packaging Cost: 

Net Cost Impact to Vehicle: 

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL CO

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 4 of 16
Cooler Assembly 1505 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loc

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loc

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specific

Component Description: Cooler Assembly - Charged Air Part Number: 1505-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL CO

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer and 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and Intransit Inventory 

Requirements 

(Parts)

Rack/Pallet Investment Amortization: $0.096 $382,979 0.00% 4,500,000 60 5.00% $420 912 63 6 57447

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: $0.096

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 5 of 16
Tube Ass'y-Waste Gate 1570A Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube Assembly - Turbo Waste Gate Pneumatic Control Part Number: 1570-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Tube Reservoir to Solenoid 1770-N0101-03-1 1 Assemble sheathing and glue on end connections. S Not Applicable General Assembly Mech. Assembly, LC 180 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.20 $0.56 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.752A Tube Reservoir to Pump 1770-N0101-03-2 1 Assemble sheathing and glue on end connections. S Not Applicable General Assembly Mech. Assembly, LC 157 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.23 $0.64 $0.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.87 $0.873A Tube - Sol to Wastegate 1770-N0101-03-4 1 Assemble sheathing S Not Applicable General Assembly Mech. Assembly, LC 300 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.12 $0.33 $0.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.45 $0.45

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Reservoir to Solenoid 1770-N0101-03-1-1 1 Extrude and Form S Nylon12, Inject. Extruding/Drawing Operator Comp./Ext. Mold, LMC 400 1.5 0.009 $3.03 $54.35 $100.04 $0.03 $0.20 $0.25 $0.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.48 $0.482A Tube Preformed 1770-N0101-03-2-1 1 Extrude and Form S Nylon12, Inject. Extruding/Drawing Operator Comp./Ext. Mold, LMC 257 1.5 0.020 $3.03 $54.35 $100.04 $0.06 $0.32 $0.39 $0.77 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.77 $0.773A Tube - Sol to Wastegate 1770-N0101-03-4-1 1 Extrude S Thermoset-SBR Extruding/Drawing Operator Comp./Ext. Mold, LMC 514 0.5 0.095 $1.32 $54.35 $100.04 $0.13 $0.05 $0.19 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Hose Tube end connections 1770-N0101-03-1-2 4 Rubber S $0.00 $0.04 $0.00 $0.16

2A Sheath Tube-Short 1770-N0101-03-1-3 1 Nylon S $0.00 $0.20 $0.00 $0.203A Sheath Tube - medium 1770-N0101-03-2-2 1 Nylon S $0.00 $0.50 $0.00 $0.504A Sheath Tube-Long 1770-N0101-03-4-2 1 Nylon S $0.00 $0.60 $0.00 $0.605A Zip Tie - tube to tube 1770-N0101-03-3 3 S $0.00 $0.02 $0.00 $0.066A Zip Tie Edge Bitter - tube to tube 1770-N0101-03-6 1 S $0.00 $0.12 $0.00 $0.127A Isolator/Hose wrap 1770-N0101-03-5 1 S $0.00 $0.08 $0.00 $0.08

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $5.41

T1 or OEM Total Manufacturing Cost: $1.93 $1.12 $2.36 $5.41 $0.00 $0.00 $0.00 $0.00 $0.00 $5.41

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.32 $0.22 $0.05 $0.61

Base Cost Impact to Vehicle: $1.93 $1.12 $2.36 $5.41 $0.02 $0.32 $0.22 $0.05 $0.61 $6.03 

Packaging Cost: $0.10

Net Cost Impact to Vehicle: $6.12

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.013 $26,596 0.00% 2,250,000 60 5.00% $200 133 432 6 57447

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: $0.09 $1.00 10 $3.00 9 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.099

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Packaging Opdividers.12 Cells per L9 Layers.Total # of Part

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 6 of 16
Tube Assembly-Inlet 1570B Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Inlet Part Number: 1570-N0101-20/21/22 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Resonator Tube Sub-Assembly 1570-N0101-21 1 Spin Weld Housing Inner to Baffle Inner S Not Applicable General Assembly Mech. Assembly, LC 300 3 0.000 $0.00 $35.51 $100.19 $0.00 $0.36 $0.33 $0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.69 $0.692A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler 1570-N0101-19 1 Assembly Tubes to Resonator S Not Applicable General Assembly Mech. Assembly, LC 200 3 0.000 $0.00 $35.51 $100.19 $0.00 $0.53 $0.50 $1.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.03 $1.03

Purchase Part - High Impact Item (Full Cost Mapping)

1A Hose Long 1570-N0101-19-2 1 Extrude and Form S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 295 1.5 0.691 $1.85 $54.35 $100.04 $1.28 $0.28 $0.34 $1.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.89 $1.891B Hose Long w. Overmold Clamp 1570-N0101-19-2 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.642A Hose Short Preformed 1570-N0101-19-6 1 Extrude and Form S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 450 1.5 0.387 $1.85 $54.35 $100.04 $0.71 $0.18 $0.22 $1.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.12 $1.123A Housing Outer Shell 1570-N0101-19-4-1 1 Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 554 0.25 0.513 $1.54 $43.52 $100.01 $0.79 $0.02 $0.18 $0.99 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.99 $0.993B Baffle Inner Tube & End Cap 1570-N0101-19-4-2 1 Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 610 0.25 0.203 $1.54 $43.52 $100.01 $0.31 $0.02 $0.16 $0.49 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.49 $0.49

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Hose Clamp 1570-N0101-19-3 3 2" S $0.00 $0.27 $0.00 $0.81

2A Sleeve Tube Anti-Crush 1570-N0101-19-4-3 2 Steel, Nickel/Zinc Plate S $0.00 $0.30 $0.00 $0.603A Hose clamp 1570-N0101-19-8 1 2" w. Retention Teeth S $0.00 $0.35 $0.00 $0.354A Grommet Fastener Isolator 1570-N0101-19-4-4 1 S $0.00 $0.08 $0.00 $0.085A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-5 1 S $0.00 $0.05 $0.00 $0.05

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $8.75

T1 or OEM Total Manufacturing Cost: $4.98 $1.61 $2.16 $8.75 $0.00 $0.00 $0.00 $0.00 $0.00 $8.75

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.53 $0.35 $0.09 $0.99

Base Cost Impact to Vehicle: $4.98 $1.61 $2.16 $8.75 $0.03 $0.53 $0.35 $0.09 $0.99 $9.74 

Packaging Cost: $0.08

Net Cost Impact to Vehicle: $9.82

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.030 $59,840 0.00% 2,250,000 60 5.00% $200 299 192 6 57447

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: $0.05 $1.00 9 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.077

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Option #1 with Part Size =600Parts per Pallelayers= 192 pa

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 7 of 16
Tube Assembly-Outlet-1570C Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Outlet Part Number: 1570-N0101-30 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Tube 1570-N0101-30-5 1 Install Inserts and Grommets S Not Applicable General Assembly Mech. Assembly, LC 240 5 0.000 $0.00 $35.51 $100.19 $0.00 $0.74 $0.42 $1.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.16 $1.16

2 Tube - Charge Air Cooler Outlet 1570-N0101-30 1 Install Hose, Clamp S Not Applicable General Assembly Mech. Assembly, LC 180 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.39 $0.56 $0.95 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.95 $0.95

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube 1570-N0101-30-5 1 Friction Weld S Not Applicable Mold/Cast/Sinter Operator Inject. Mold, SMS 180 3 0.000 $0.00 $43.52 $100.01 $0.00 $0.73 $0.56 $1.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.28 $1.281B Tube 1570-N0101-30-5-2 1 Extrude & Blow Form Tube S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 145 1 1.612 $1.59 $43.52 $100.01 $2.56 $0.30 $0.69 $3.55 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.55 $3.552A Tube Attachment #1 1570-N0101-30-5-31 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.25 0.015 $1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.183A Tube Attachment #2 1570-N0101-30-5-32 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.25 0.015 $1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.184A Tube Attachment #3 1570-N0101-30-5-33 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.25 0.015 $1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.185A Hose preformed 1570-N0101-30-3 1 Extrude and Form S SBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC 367 1.5 0.676 $1.85 $54.35 $100.04 $1.25 $0.22 $0.27 $1.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.74 $1.745B Hose w/Clamps 1570-N0101-30-1 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.64

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Insert Brass Threaded 1570-N0101-30-6 1 S $0.00 $0.04 $0.00 $0.04

2A Sleeve Tube Anti-Crush 1570-N0101-19-4-3 2 S $0.00 $0.30 $0.00 $0.603A Grommet Fastener Isolator 1570-N0101-19-4-4 1 S $0.00 $0.08 $0.00 $0.084A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-5 1 S $0.00 $0.05 $0.00 $0.055A Nut - Flag w/Isolator 1570-N0101-30-7 1 S $0.00 $0.25 $0.00 $0.256A Sleeve Anti Crush 1570-N0101-30-8 1 S $0.00 $0.30 $0.00 $0.307A Hose Clamp 1570-N0101-30-4 2 S $0.00 $0.29 $0.00 $0.588A Sensor - Intake Temperature, Outlet Charged Air Co 1599-N0101-03 1 S $0.00 $5.00 $0.00 $5.009A Bolt - Sensor, Charge Air Temperature 1580-N0101-10 1 S $0.00 $0.04 $0.00 $0.04

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $16.81

T1 or OEM Total Manufacturing Cost: $10.83 $2.65 $3.32 $16.81 $0.00 $0.00 $0.00 $0.00 $0.00 $16.81

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.05 $1.01 $0.67 $0.17 $1.90

Base Cost Impact to Vehicle: $10.83 $2.65 $3.32 $16.81 $0.05 $1.01 $0.67 $0.17 $1.90 $18.70 

Packaging Cost: $0.06

Net Cost Impact to Vehicle: $18.76

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.057 $227,394 0.00% 4,500,000 60 5.00% $380 598 96 6 57447

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

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Pallet Option #Part Size = 60Parts per PalleLayers = 96 Pa

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 8 of 16
Tube Assembly-Outlet-1570D Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube - Elbow, Upper to Charged Air Coupler By-Pass Part Number: 1570-N0101-40 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

Tube - Elbow, Upper to Charged Air Coupler ByPas 1570-N0101-40 1 Crimp End Hose Piece onto Hose and Add O-Ring S Not Applicable General Assembly Mech. Assembly, LC 240 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.15 $0.42 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $0.57

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube (Hose) preformed 1570-N0101-40-1 1 Extrude and Form S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 400 1.5 0.620 $1.85 $54.35 $100.04 $1.15 $0.20 $0.25 $1.60 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.60 $1.601B Tube (Hose) w/Clamps 1570-N0101-40-1-1 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.64

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

Hose Clamp 1570-N0101-40-2 1 S $0.00 $0.25 $0.00 $0.25

Hose end piece 1570-N0101-40-3 1 S $0.00 $0.75 $0.00 $0.75O-ring Seal Tube OD 1570-N0101-40-4 1 S $0.00 $0.11 $0.00 $0.11

0 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $3.92

T1 or OEM Total Manufacturing Cost: $2.26 $0.58 $1.08 $3.92 $0.00 $0.00 $0.00 $0.00 $0.00 $3.92

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.24 $0.16 $0.04 $0.44

Base Cost Impact to Vehicle: $2.26 $0.58 $1.08 $3.92 $0.01 $0.24 $0.16 $0.04 $0.44 $4.36 

Packaging Cost: $0.03

Net Cost Impact to Vehicle: $4.39

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.010 $19,947 0.00% 2,250,000 60 5.00% $200 100 576 6 57447

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: $0.02 $1.00 10 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.027

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Package OptioPart Size = 20Each Layer = 4 Number of LayTotal Parts pe

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 9 of 16
Tube Inlet ETB-1570 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Met

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Part Number: 1570-N0101-41/42/43/44 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

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

1A Flex Tube Silencer to Environment 1070-N0101-05-3 (1570-N0101-44) 1 Heat Stake Cap to Flex Tube and add foam. S Not Applicable General Assembly Mech. Assembly, LC 240 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.15 $0.42 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $2A Silencer - Charge Air By-Pass 1070-N0101-05-2 (1599-N0101-04) 1 Insert Inner Baffle and Vibration Weld Housing S Not Applicable General Assembly Mech. Assembly, LC 240 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.15 $0.42 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $3A Hose Ass'y Silencer to Y Couple (Tube - Charged Air Bypass to Silencer) 1070-N0101-05-5 (1570-N0101-43) 1 Assemble Protective Sheath and Isolator S Not Applicable General Assembly Mech. Assembly, LC 300 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.12 $0.33 $0.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.45 $4A Tube Inlet to throttle body 1070-N0101-05 (1570-N0101-42) 1 Assemble Individual Tube Assemblies with clamps S Not Applicable General Assembly Mech. Assembly, LC 120 4 0.000 $0.00 $35.51 $100.19 $0.00 $1.18 $0.83 $2.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.02 $

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube - Flex Elbow, Silencer to Environment 1070-N0101-05-15-1 (1570-N0101-44) 1 Injection Mold S TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 710 1 0.205 $0.99 $43.52 $100.01 $0.20 $0.06 $0.14 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $2A Tube - Flex Elbow, Silencer to Environment, Snap 1070-N0101-05-15-2 (1570-N0101-44) 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.5 0.020 $1.59 $43.52 $100.01 $0.03 $0.03 $0.14 $0.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.20 $3A Silencer Outer Shell 1070-N0101-05-2-1 1 Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 509 0.5 0.270 $1.45 $43.52 $100.01 $0.39 $0.04 $0.20 $0.63 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.63 $4A Silencer Inner Baffle 1070-N0101-05-2-1-2-3 1 Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 986 0.5 0.140 $1.45 $43.52 $100.01 $0.20 $0.02 $0.10 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $5A Silencer End Cap 1070-N0101-05-2-1-2 1 Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 900 0.5 0.140 $1.45 $43.52 $100.01 $0.20 $0.02 $0.11 $0.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.34 $6A Tube (Hose) preformed 1570-N0101-40-1 1 Extrude and Form S SBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC 383 1.5 0.380 $1.85 $54.35 $100.04 $0.70 $0.21 $0.26 $1.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.18 $7A Tube Y-Coupler to bypass 1070-N0101-05-8-1 (1570-N0101-41) 1 Injection Mold S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 923 0.5 0.289 $1.76 $43.52 $100.01 $0.51 $0.02 $0.11 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $8A Elbow Coupler Bypass to Throttle (Tube-Elbow Coupler By-Pass to Throttle Body) 1070-N0101-05-10-1 (1570-N0101-42) 1 Extrude and Form S SBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC 343 1.5 0.723 $1.85 $54.35 $100.04 $1.34 $0.24 $0.29 $1.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.87 $8B Elbow Coupler Bypass to Throttle w. Clamp (Tube-Elbow Coupler By-Pass to Throttle Body) 1070-N0101-05-11 (1570-N0101-42) 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase Price 

Net, PIA

Purch

Net, 

1A Seal foam press in place tape style 1070-N0101-05-16 1 S $0.00 $0.10 $0.00 $

2A Grommet - Silencer to Engine 1070-N0101-05-99 1 S $0.00 $0.15 $0.00 $3A Sheath Hose Protection 1070-N0101-05-14 1 S $0.00 $0.38 $0.00 $4A Isolator Hose 1070-N0101-05-7 1 S $0.00 $0.12 $0.00 $5A Hose Clamp lrg end molded in place 1070-N0101-05-12 1 S $0.00 $0.40 $0.00 $

6a Hose Clamp sml end 1070-N0101-05-11 1 S $0.00 $0.27 $0.00 $7a Hose Clamp 1070-N0101-05-4 3 S $0.00 $0.16 $0.00 $

0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $

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

T1 or OEM Total Manufacturing Cost: $5.48 $2.48 $3.77 $11.73 $0.00 $0.00 $0.00 $0.00 $0.00 $1

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.04 $0.70 $0.47 $0.12 $1.33

Base Cost Impact to Vehicle: $5.48 $2.48 $3.77 $11.73 $0.04 $0.70 $0.47 $0.12 $1.33 $1

Packaging Cost: $

Net Cost Impact to Vehicle: $1

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

TOTAL COS

10

9,574

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 10 of 16
Tube Inlet ETB-1570 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Met

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Part Number: 1570-N0101-41/42/43/44 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

TOTAL COS

10

9,574

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer and 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and Intransit Inventory 

Requirements 

(Parts)

Rack/Pallet Investment Amortization: $0.066 $131,649 0.00% 2,250,000 60 5.00% $220 598 96 6 57447

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: $0.066

Pallet OptCell ReturPart Size: Parts/LayeNumber o

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 11 of 16
Bracket-Support Turbo 1575 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Bracket - Support, Turbo Assembly Part Number: 1575-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

Bracket - Support, Turbo Assembly 1575-N0101-01 (1275-N0101-04) 1 Forging S S-Steel-304, Bar Forging Operator Cold Forge, LMC 257 1 0.649 $1.65 $38.52 $100.09 $1.07 $0.15 $0.39 $1.61 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.61 $1.61

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

0 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $1.61

T1 or OEM Total Manufacturing Cost: $1.07 $0.15 $0.39 $1.61 $0.00 $0.00 $0.00 $0.00 $0.00 $1.61

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.10 $0.06 $0.00 $0.17

Base Cost Impact to Vehicle: $1.07 $0.15 $0.39 $1.61 $0.00 $0.10 $0.06 $0.00 $0.17 $1.78 

Packaging Cost: $0.06

Net Cost Impact to Vehicle: $1.84

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.001 $1,596 0.00% 2,250,000 60 5.00% $100 16 3600 6 57447

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: $0.06 $0.00 0 $0.00 0 $3.50 60 $0.00 0 $0.00 0

Packaging Cost Total: $0.059

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Packaged in EBoxes(Weight ConsiCard Board Bo($3.50/Box)Parts per Box: Layers/Box = 6Per Pallet (1/2 layer3 layers = 60 B

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 12 of 16
Vac. Reservoir 1599 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Vacuum Reservoir - Turbo Waste Gate Part Number: 1599-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Vacuum Reservoir 7070-N0101-02 (1599-N01010-01) 1 Vibration Weld and Assembly Inserts S Not Applicable General Assembly Mech. Assembly, LC 240 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.30 $0.42 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.71 $0.71

Purchase Part - High Impact Item (Full Cost Mapping)

1A Cover - cap: Vacuum Reservoir 7070-N0101-02-1 1 PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 1037 0.5 0.158 $1.76 $43.52 $100.01 $0.28 $0.02 $0.10 $0.40 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.44 $0.442A Base Reservoir: Vacuum Reservoir 7070-N0101-02-2 1 PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 861 0.5 0.454 $1.76 $43.52 $100.01 $0.80 $0.03 $0.12 $0.94 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.04 $1.04

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Anti-Crush Sleeves Vacuum Reservoir 7070-N0101-02-3 3 $0.00 $0.04 $0.12 $0.00

0 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $2.19

T1 or OEM Total Manufacturing Cost: $1.08 $0.34 $0.63 $2.05 $0.00 $0.08 $0.05 $0.00 $0.14 $2.19

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.14 $0.13 $0.05 $0.34

Base Cost Impact to Vehicle: $1.08 $0.34 $0.63 $2.05 $0.01 $0.22 $0.18 $0.05 $0.48 $2.53 

Packaging Cost: $0.10

Net Cost Impact to Vehicle: $2.63

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.017 $33,497 0.00% 2,250,000 60 5.00% $200 167 343 6 57447

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 $1.00 8 $3.00 7 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.101

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Pallet Option #PadsPart Size:170xParts Layer = Number of Lay

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 13 of 16
Valve-Thrust Control 1599 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Value - Thrust Control, Turbo Waste Gate Pneumatic Control Part Number: 1599-N0101-02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Value - Thrust Control, Turbo Waste Gate Pneumatic Control 1599-N0101-02 1 (Look @ Evaluating as Low Impact Supplier) S $0.00 $5.19 $0.00 $5.19

0 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.000 $0.00 $0.00 $0.00 $0.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $5.19

T1 or OEM Total Manufacturing Cost: $5.19 $0.00 $0.00 $5.19 $0.00 $0.00 $0.00 $0.00 $0.00 $5.19

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.34 $0.31 $0.13 $0.80

Base Cost Impact to Vehicle: $5.19 $0.00 $0.00 $5.19 $0.03 $0.34 $0.31 $0.13 $0.80 $5.99 

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $6.02

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.024 $48,980 0.00% 2,250,000 60 5.00% $4,420 11 5184 6 57447

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: $0.024

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Packaging OpTraysPart Size 80x9Parts/Layer = Number of Lay

"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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 14 of 16
Engine Assembly 1500 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine And Vehicle Assembly Part Number: 1500-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) 

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

1A Turbo Charging Assembly 1501-N0101-01 1 Mount Turbo Assembly to Intake Manifold, 4 Nuts OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 82 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.02 $1.53 $2.55 0.00% 0.00% 2A Bracket - Support, Turbo Assembly 1575-N0101-01 1 Install Turbo Support Bracket, 2 Bolts OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 97 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.86 $1.29 $2.14 0.00% 0.00% 3A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-01 1 Install Vacuum Reservoir, 2 Bolts and 1 Nut OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 90 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.93 $1.39 $2.32 0.00% 0.00% 4A Value - Thrust Control, Turbo Waste Gate Pneumatic Control 1599-N0101-02 1 Install Valve to Mount Bracket, No Additional Fastener OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 240 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.35 $0.52 $0.87 0.00% 0.00% 5A Tube Assembly - Turbo Waste Gate Pneumatic Control 1570-N0101-03 1 Install Waste Gate Tubing, 6 Attachment Points OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 73 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.13 $1.70 $2.84 0.00% 0.00% 6A Cooler Assembly - Charged Air 1505-N0101-01 1

Install Vehicle H/W for Charged Air Cooler and Charged Air Cooler.

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 49 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.71 $2.57 $4.29 0.00% 0.00% 

7A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Inlet 1570-N0101-20/21/22 1 Install Tube Assembly, Turbo Assembly to Charged Air Cooler OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 75 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.11 $1.67 $2.78 0.00% 0.00% 8A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Outlet 1570-N0101-30 1 Install Tube Assembly, Charged Air Cooler to Coupler/ETB bypass OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 61 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.37 $2.05 $3.42 0.00% 0.00% 9A Tube - Elbow, Upper to Charged Air Coupler By- Pass 1570-N0101-40 1

Make Connection Between Charged Air Outlet Tube and Electronic Throttle Body Inlet Tube.

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 189 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.44 $0.66 $1.10 0.00% 0.00% 

10A

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

1570-N0101-41/42/43/44 1

Make Connection to Throttle 

Body and Snap in Bypass Tube to Vehicle Body

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 92 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.90 $1.36 $2.26 0.00% 0.00% 

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

1A Turbo Charging Assembly 1501-N0101-01 1 SAC 

2A Bracket - Support, Turbo Assembly 1575-N0101-01 1 SAC 3A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-01 1 SAC 4A Value - Thrust Control, Turbo Waste Gate Pneumatic Control 1599-N0101-02 1 SAC 5A Tube Assembly - Turbo Waste Gate Pneumatic Control 1570-N0101-03 1 SAC 6A Cooler Assembly - Charged Air 1505-N0101-01 1 SAC 7A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Inlet 1570-N0101-20/21/22 1 SAC 8A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Outlet 1570-N0101-30 1 SAC 9A Tube - Elbow, Upper to Charged Air Coupler By- Pass 1570-N0101-40 1 SAC 

10A

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

1570-N0101-41/42/43/44 1 SAC 

11A Nut - Exhaust Manifold to Turbo 1280-N0101-07 4 S 12A Bolt - Bracket Support, Turbo Assembly 1580-N0101-03 1 S 13A Bolt - Bracket Support, Turbo Assembly 1580-N0101-04 1 S 14A Bolt - Pressure Reservoir, Turbo Waste Gate 1580-N0101-05 2 S 15A Nut - Pressure Reservoir, Turbo Waste Gate 1580-N0101-06 1 S 16A Bolt - Tube, Charge Air Cooler to Vehicle 1580-N0101-09 2 Hardware Not Available S 17A Internal Threaded Part ( Vehicle H/W) NA 2 Hardware Not Available S 18A Isolators Veh. Mnt. Charged Air Cooler NA 2 S 19A Bolt - Tube Ass'y w. Vehicle Canister Tie Down 

....

NA 1 Hardware Not Available S 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for 

both Technology Packages)

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 15 of 16
Engine Assembly 1500 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine And Vehicle Assembly Part Number: 1500-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) SG&A Rate (DB) 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for 

both Technology Packages)

20A Internal Threaded Part ( Vehicle H/W Inlet (1 pc) & Outlet (2 pcs) Air Tube Canister Tie Down) NA 3 Hardware Not Available S 21A Bolt - Tube Charged Air Cooler Outlet NA 2 Hardware Not Available S 22A Screw Tube Intake Manifold to Attachment NA 1 Hardware Not Available S 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $221.21 $9.81 $14.75 $245.77 $0.00 $0.00 

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

(SAC) &T1 or OEM Mark-Up Values: (220.07) ----- ----- ----- $0.00 $0.00 

Base Cost Impact to Vehicle: $1.14 $9.81 $14.75 $25.70 $0.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/ 

Racks Required

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.000

 PACKAGING CALCULATIONS: No Packaging Considerations Required. Packaging Costs for fasteners (bolts, nuts, etc.) is captured in the piece costs.

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 16 of 16
Appendix G.1 - Subsystem 17

Breather Subsystem

 Case Study #0101

MAQS Worksheets

File:Breather Subsystem 17 040209.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-17, 1 of 2
Oil-Air Separator 1702 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Oil/Air Separator Part Number: 1702-N0101-00 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Oil/Air Separator 1702-N0101-00 1 Final Assembly of PCV system to cover. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 3 0.000 $0.00 $35.51 $15.00 $45.00 $0.00 $0.14 $0.18 $0.31 0.00% 0

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

Purchase Part - High Impact Item (Full Cost Mapping)

1A

Valve - Non Return Intake Hose & Manifold Side

1702-N0101-01/41-01 2 Injection Mold Flap with overmold Hinge T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 1 1 1 0.005 $1.54 $43.52 $100.01 $100.01 $0.01 $0.06 $0.14 $0.21 0.50% 6

1B

Valve - Non Return Intake Hose & Manifold Side

1702-N0101-01/41-02 2 Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS 800 0 1 1 0.002 $1.27 $43.52 $100.01 $100.01 $0.00 $0.00 $0.13 $0.13 0.50% 6

2A Separator - Cyclone 1702-N0101-10 1

Injection Mold (Additional Plastic added to Mini Cover over GEMA cover)

T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 545 0 1 1 0.818 $1.54 $43.52 $150.01 $150.01 $1.26 $0.00 $0.28 $1.53 0.50% 6

3A Valve - Pressure Control 1702-N0101-20 1 Nylon Injection Mold T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 391 1 1 1 0.005 $1.54 $43.52 $100.01 $100.01 $0.01 $0.11 $0.26 $0.37 0.50% 63B Valve - Pressure Control 1702-N0101-20 1 Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS 389 0 1 1 0.002 $1.27 $43.52 $100.01 $100.01 $0.00 $0.00 $0.26 $0.26 0.50% 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 

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

1A Hinge Flow control flap 1702-N0101-80 2 S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.35 $0.37 $1.49 $3.21 $0.01 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6

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

Base Cost Impact to Vehicle: $1.35 $0.37 $1.49 $3.21 $0.03 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: No Packaging Impact

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Breather Subsystem 17 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-17, 2 of 2
Appendix G.1 - Subsystem 60

Engine Management, Engine 

Electronic, and Electrical 

Subsystems

 Case Study #0101

MAQS Worksheets

File:Electrical Subsystem 6000 040209.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-60, 1 of 5
PCM HW 6002A Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Power Train Control Module (PCM) Assembly - Hardware Part Number: 0602-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Power Train Control Module (PCM) Assembly - Hardware 0602-N0101-01 1

The PCM H/W is carry over 

except for the PFI drivers. GDI drivers use a 75-80VDC Boost Circuit and 25A Peak/Hold Drivers. The turbo is just another lowside driver really no cost. 

S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $40.00 $0.00 $0.00 $40.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $40.00 $0.00 $0.00 $40.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: NAPart Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes costing for both Technology Packages)

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 2 of 5
PCM SW 6002B Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Power Train Control Module (PCM) Assembly - Software Part Number: 6002-N0101-50 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

1A Power Train Control Module (PCM) Assembly - Software 6002-N0101-50 1

• Control system is much more complicated in order to control injection timing, split injections, fuel rail pressure, electric water pump, electric thermostat, etc.

S 

0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

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

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type: NAPart Size:Parts/Layer:Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes costing for both Technology Packages)

Per discussion with Brian Nelson, Software will be covered by indirect cost multiplier.5/20/09

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 3 of 5
Electrical 6003 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets) Part Number: 6003-N0101-01/30 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)Purchase Part - Commodity ( Value taken from Purchase Part Database)

1A Wire Turbo Connector 0603-N0101-30 2 ($0.50/Wire Circuit) S 

2A Wire Coolant Aux Pump 0603-N0101-30 3 ($0.50/Wire Circuit) S 3A Clip Harness Retention 2 S 4A Wire Waste Gate Sol 0603-N0101-30 2 ($0.50/Wire Circuit) S 5A Wire Charge Air Temp 0603-N0101-30 4 ($0.50/Wire Circuit) S 6A Clip Harness Retention 1 S 7A Edge Biter Harness Retention 3 S 8A Wire HP Fuel Pump Control 2 ($0.50/Wire Circuit) S 9A Wire Fuel Pressure Sensor 0603-N0101-30 3 ($0.50/Wire Circuit) S 

10A Ignition Coil Assembly - Single Spark 0603-N0101-01 4 S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $12.13 $0.00 $0.00 $12.13 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $12.13 $0.00 $0.00 $12.13 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Negligible Change to Packaging

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 4 of 5
Engine Assembly 6000 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets) Part Number: 6003-N0101-01-50 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

Additional Electrical Connections due to Turbo & DI Adds NA 1 Install Connectors, Secure Wiring OEM Engine Assembly Not Applicable General Assembly-OEM Engine Assembly, OEM 52 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $1.60 $2.88 $4.48 0.00% 0

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

1A Power Train Control Module (PCM) Assembly - Hardware 0602-N0101-01 1 SAC 

2A Power Train Control Module (PCM) Assembly - Software 6002-N0101-50 1 SAC 3A

Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

0603-N0101-01/30 1 SAC 

4A 5A 6A 7A 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $52.13 $1.60 $2.88 $56.61 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (52.13) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $0.00 $1.60 $2.88 $4.48 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Negligible Change to Packaging

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 5 of 5
Appendix G.1 - Subsystem 70

Accessory Subsystem

 Case Study #0101

MAQS Worksheets

File:70 Accessory System 040209.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-70, 1 of 4
Vacuum Pump Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Vacuum Pump Assembly Part Number: 7004-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Vacuum Pump Assembly 7004-N0101-01 1 Final Assembly & Test Vacuum Pump S Not Applicable General Assembly Mech. Assembly, MC 240 3 0.000 $0.00 $35.51 $125.19 $0.00 $0.44 $0.52 $0.97 0.00% 0.00% 0.00% 0.00% 01B Base Vac Pump Rotor Support 7004-N0101-01-07-01 1 Subassembly Exhaust and Oil Vent Valve S Not Applicable General Assembly Mech. Assembly, MC 240 1 0.000 $0.00 $35.51 $125.19 $0.00 $0.15 $0.52 $0.67 0.00% 0.00% 0.00% 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Base Vac Pump rotor support Casting 7004-N0101-01-07-01-02 1 Machine Casting S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC 257 1 0.000 $0.00 $43.52 $100.05 $0.00 $0.17 $0.39 $0.56 0.30% 6.00% 4.00% 0.00% 101B Base Vac Pump rotor support Casting 7004-N0101-01-07-01-02-1 1 Casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 183 0.5 0.542 $1.10 $43.52 $100.05 $0.60 $0.12 $0.55 $1.26 0.30% 6.00% 4.00% 0.00% 102A Plate Oil vent relief 7004-N0101-01-07-01-04 1 Stamping & Heat Treat S SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.25 0.005 $0.65 $42.18 $100.10 $0.00 $0.01 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 103A Plate retainer/limiter - Oil vent relief 7004-N0101-01-07-01-05 1 Stamping & Plating S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.25 0.008 $0.45 $42.18 $100.10 $0.00 $0.01 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 104A Rotor Vac Pump 7004-N0101-01-08 1 Induction Harden S Not Applicable Lathe/Turning Operator CNC Turning, MHC 600 0.15 0.000 $0.00 $37.60 $125.00 $0.00 $0.01 $0.21 $0.22 0.30% 6.00% 4.00% 0.00% 104B Rotor Vac Pump 7004-N0101-01-08 1 Machine for Critical Tol. S Not Applicable Lathe/Turning Operator CNC Turning, MHC 109 0.85 0.000 $0.00 $37.60 $125.00 $0.00 $0.29 $1.15 $1.44 0.30% 6.00% 4.00% 0.00% 10

4C Rotor Vac Pump raw part 7004-N0101-01-08-1-1 1 PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, MHC 240 0.5 0.631 $2.00 $43.52 $150.14 $1.26 $0.09 $0.63 $1.98 0.30% 6.00% 4.00% 0.00% 10

5A Adapter Rotor Drive 7004-N0101-01-09 1 PM Sinter S PM-SMF-FC0208 Mold/Cast/Sinter Operator Powder Metal, LMC 360 0.5 0.139 $1.00 $43.52 $100.14 $0.14 $0.06 $0.28 $0.48 0.30% 6.00% 4.00% 0.00% 106A Retainer Rotor drive adapter 7004-N0101-01-10 1 Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1200 0.25 0.001 $0.45 $42.18 $100.10 $0.00 $0.01 $0.08 $0.09 0.30% 6.00% 4.00% 0.00% 107A Vane Vacuum Pump 7004-N0101-01-05 1 Form Edges and Plate S Not Applicable Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.25 0.000 $0.00 $42.18 $100.10 $0.00 $0.01 $0.14 $0.15 0.30% 6.00% 4.00% 0.00% 107B Vane Vacuum Pump 7004-N0101-01-05-01 1 Stamp Out Form S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1200 0.25 0.167 $0.45 $42.18 $100.10 $0.08 $0.01 $0.08 $0.17 0.30% 6.00% 4.00% 0.00% 108A Seal Pump Vane to wall 7004-N0101-01-06 2 PM Sinter S Not Applicable Mold/Cast/Sinter Operator Powder Metal, LMC 600 0.25 0.000 $0.00 $43.52 $100.14 $0.00 $0.02 $0.17 $0.19 0.30% 6.00% 4.00% 0.00% 108B Seal Pump Vane to wall 7004-N0101-01-06-01 2 PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, LMC 480 0.25 0.026 $2.00 $43.52 $100.14 $0.05 $0.02 $0.21 $0.28 0.30% 6.00% 4.00% 0.00% 109A Cover Vacuum Pump 7004-N0101-01-01 1 Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 180 1 1.070 $0.45 $42.18 $100.10 $0.48 $0.23 $0.56 $1.27 0.30% 6.00% 4.00% 0.00% 10

10A Fitting Vac Outlet Port 7004-N0101-01-03 1 Assemble Outlet Fitting S Purchased Parts General Assembly Mech. Assembly, LC 450 1 0.265 $1.00 $35.51 $100.19 $0.27 $0.08 $0.22 $0.57 0.30% 6.00% 4.00% 0.00% 1010B Fitting Vac Outlet Port 7004-N0101-01-03-01 1 Injection Mold Housing S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 480 0.25 0.014 $1.54 $43.52 $100.01 $0.02 $0.02 $0.21 $0.25 0.30% 6.00% 4.00% 0.00% 10

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

1A Fitting Clean Air Inlet 7004-N0101-01-07-01-03 1 S 2A Rivet solid, Oil vent plates 7004-N0101-01-07-01-06 1 S 3A Gasket Vac Pump Cover (SBR) 7004-N0101-01-02 1 S 4A Bolt - Vacuum Pump Housing 7080-N0101-10 4 S 5A Sleeve Anti Crush 7004-N0101-01-03-02 1 B10A 5B Check Valve 7004-N0101-01-03-03 1 B10A 

5C Spring Check Valve 7004-N0101-01-03-04 1 B10A 5D Seat check valve spring 7004-N0101-01-03-05 1 B10A 

5E O-Ring - Vac fitting 7004-N0101-01-04 1 B10A 6A Bolt - Vac Fitting 7080-N0101-10 1 S 

T1 or OEM Total Manufacturing Cost: $3.31 $1.81 $6.56 $11.69 $0.03 $0.58 $0.39 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15

T1 or OEM Mark-Up Values: ----- ----- ----- ----- $0.06 $0.82 $0.76 $0.32 $

Base Cost Impact to Vehicle: $3.31 $1.81 $6.56 $11.69 $0.09 $1.41 $1.15 $0.32 $

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-70, 2 of 4
Vacuum Pump Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Vacuum Pump Assembly Part Number: 7004-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Packaging Calculations Cost per Piece Total Amount Lump Sum Payment (%) Total # of Pieces Number of Months Interest Rate Cost per Pallet /Rack

Total 

Number of 

Pallets/ 

Racks 

Required

Number of 

Parts per 

Pallet/ Rack

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.018 $35,461 0.00% 2,250,000 60 5.00% $200 177 432 

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

O

Pal

Expendable Packaging in Piece Cost: $0.08 $1.00 9 $3.00 8 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.094

File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-70, 3 of 4
Engine Assembly Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly of Accessory Subsystem Components to Engine Part Number: 7000 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description OEM/Supplier Classification Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing 

Multiplier

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Applied Burden Rate $/Hour Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate (DB) S

R

(

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

Vacuum Pump Assembly 7004-N0101-01 1 Mount Vacuum Pump to Head OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 113 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.74 $1.34 $2.08 0.00% 0

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

Bolt - Vacuum Pump 7080-N0101-01 2 S 

Seal - Vacuum Pump to Head 7004-N0101-01-11 1 S 

0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $0.13 $0.74 $1.34 $2.20 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $0.13 $0.74 $1.34 $2.20 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging for fasteners covered in piece price.

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

Full Quote Modification Quote Differential Quote (Quote Summary includes 

File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-70, 4 of 4
APPENDIX H.1 

Subsystem Cost Model Analysis Templates

Case Study #0101

Appendix H.1

Printed:12/9/2009

$0.00

Crank Drive Subsystem Appendix H.1 - 03, Pages 2-4 $0.00

Counter Balance Subsystem Appendix H.1 - 04, Pages 5-7 ($35.95)

Cylinder Block Subsystem Appendix H.1 - 05, Pages 8-10 $0.44

Cylinder Head Subsystem Appendix H.1 - 06, Pages 11-13 $16.55

Valve Train Subsystem Appendix H.1 - 07, Pages 14-16 $10.06

Timing Drive Subsystem Appendix H.1 - 08, Pages 17-19 $1.60

Accessory Drive Subsystem Not Applicable $0.00

Intake Subsystem Appendix H.1 - 10, Pages 20-22 ($12.73)

Fuel Induction Subsystem Appendix H.1 - 11, Pages 23-25 $107.32

Exhaust Subsystem Appendix H.1 - 12, Pages 26-28 $37.77

Lubrication (Oil Pans/Sumps) Subsystem Appendix H.1 - 13, Pages 29-31 $34.46

Cooling Subsystem Appendix H.1 - 14, Pages 32-34 $41.56

Induction Air Charging Subsystem Appendix H.1 - 15, Pages 35-37 $258.89

Exhaust Gas Re-Circulations Subsystem Not Applicable $0.00

Breather Subsystem Appendix H.1 - 17, Pages 38-40 $4.17

Appendix H.1 - 60, Pages 41-43 $56.61

Appendix H.1 - 70, Pages 44-46 $16.95

$537.70

Accessory (e.g. Starter Motor, Power Steering 

Pump, Air Conditioning Compressor) Subsystem

Engine Frames, Mountings & Brackets Subsystem

Engine Management, Engine Electronic and 

Electrical Subsystem

Engine Subsystems

Subsystem CMAT 

Locations within Appendix 

H.1

Not Applicable

Total Unit Cost =>

Net Incremental 

Component/Assembly Cost 

Impact to OEM

File:SUBSYS_CMAT-H.1.xls

EPA Contract:EP-C-07-069 WA1-3 H.1, Page 1 of 46
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

R&D

03 Crank Drive Subsystem

01 Crank Shaft

A. Shaft - Crank 03 01 - N0101 - 01 1 Diff. $ (10.61) $ - - $ $ (10.61) $ (0.74) (0.07) $ (0.85) $ $ - 

03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

A Rod Subassembly - Connecting 03 03 - N0101 - 01 4 Diff. 1.19 $ - $ 1.11 $ $ 2.30 $ 0.15 0.01 $ 0.14 $ 0.0

$ 

A1 Bushing - Connecting Rod 03 03 - N0101 - 02 4 PIA Rod SubassemblyA2 Rod - Connecting 03 03 - N0101 - 03 4 PIA Rod SubassemblyB Cap- Connecting Rod 03 03 - N0101 - 04 4 PIA Rod Subassembly

04 Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins, Circlips)

A Piston - Engine, Machined 03 04 - N0101 - 01 4 Diff. $ (0.36) $ 3.04 0.39 $ $ 3.07 $ 0.22 0.34 $ 0.20 $ 0.0

$ 

B Ring/Clip - Piston Pin Retainer 03 04 - N0101 - 02 8 Purchase Parts Engine Ass'yC Pin- Piston 03 04 - N0101 - 03 4 Purchase Parts Engine Ass'yD Compression Ring - Piston, Top 03 04 - N0101 - 04 4 Purchase Parts Engine Ass'yE Compression Ring - Piston, 2nd 03 04 - N0101 - 05 4 Purchase Parts Engine Ass'y

F Oil Ring Subassembly

F1 Spacer/Expander/Coil Spring - Oil Ring, Piston 03 04 - N0101 - 07 4 Purchase Parts Engine Ass'y

F2 Rail(s) - Oil Ring, Piston 03 04 - N0101 - 08 4 Purchase Parts Engine Ass'y

90 Bearing Elements: Connecting Rod Bearing Shells, Connecting Rod Bush

A Bearing - Connecting Rod to Crank Shaft 03 90 - N0101 - 01 8 Purchase Parts Engine Ass'y

100 Engine Assembly

A Assembly of Crank Drive Subsystem Components to Engine 03 00 - N0101 - 01 NA Diff. $ - 5.69 $ - $ $ 5.69 $ - - $ - $ - $ 

($4.09) $ 4.15 0.39 $ $ 0.46 $ 0.28 $ (0.51) (0.37) $ $ 0.1

NOTES:

1.

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

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

Markup 

Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-03, 2 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

03 Crank Drive Subsystem

01 Crank Shaft

A. Shaft - Crank 03 01 - N0101 - 01 1 Diff.

03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

A Rod Subassembly - Connecting 03 03 - N0101 - 01 4 Diff.

A1 Bushing - Connecting Rod 03 03 - N0101 - 02 4 PIA Rod Subassembly

A2 Rod - Connecting 03 03 - N0101 - 03 4 PIA Rod SubassemblyB Cap- Connecting Rod 03 03 - N0101 - 04 4 PIA Rod Subassembly

04 Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins, Circlips)

A Piston - Engine, Machined 03 04 - N0101 - 01 4 Diff.

B Ring/Clip - Piston Pin Retainer 03 04 - N0101 - 02 8 Purchase Parts Engine Ass'yC Pin- Piston 03 04 - N0101 - 03 4 Purchase Parts Engine Ass'yD Compression Ring - Piston, Top 03 04 - N0101 - 04 4 Purchase Parts Engine Ass'yE Compression Ring - Piston, 2nd 03 04 - N0101 - 05 4 Purchase Parts Engine Ass'y

F Oil Ring Subassembly

F1 Spacer/Expander/Coil Spring - Oil Ring, Piston 03 04 - N0101 - 07 4 Purchase Parts Engine Ass'y

F2 Rail(s) - Oil Ring, Piston 03 04 - N0101 - 08 4 Purchase Parts Engine Ass'y

90 Bearing Elements: Connecting Rod Bearing Shells, Connecting Rod Bush

A Bearing - Connecting Rod to Crank Shaft 03 90 - N0101 - 01 8 Purchase Parts Engine Ass'y

100 Engine Assembly

A Assembly of Crank Drive Subsystem Components to Engine 03 00 - N0101 - 01 NA Diff.

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup 

Manufacturing 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-03, 3 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

03 Crank Drive Subsystem

01 Crank Shaft

A. Shaft - Crank 03 01 - N0101 - 01 1 Diff.

03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

A Rod Subassembly - Connecting 03 03 - N0101 - 01 4 Diff.

A1 Bushing - Connecting Rod 03 03 - N0101 - 02 4 PIA Rod Subassembly

A2 Rod - Connecting 03 03 - N0101 - 03 4 PIA Rod SubassemblyB Cap- Connecting Rod 03 03 - N0101 - 04 4 PIA Rod Subassembly

04 Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins, Circlips)

A Piston - Engine, Machined 03 04 - N0101 - 01 4 Diff.

B Ring/Clip - Piston Pin Retainer 03 04 - N0101 - 02 8 Purchase Parts Engine Ass'yC Pin- Piston 03 04 - N0101 - 03 4 Purchase Parts Engine Ass'yD Compression Ring - Piston, Top 03 04 - N0101 - 04 4 Purchase Parts Engine Ass'yE Compression Ring - Piston, 2nd 03 04 - N0101 - 05 4 Purchase Parts Engine Ass'y

F Oil Ring Subassembly

F1 Spacer/Expander/Coil Spring - Oil Ring, Piston 03 04 - N0101 - 07 4 Purchase Parts Engine Ass'y

F2 Rail(s) - Oil Ring, Piston 03 04 - N0101 - 08 4 Purchase Parts Engine Ass'y

90 Bearing Elements: Connecting Rod Bearing Shells, Connecting Rod Bush

A Bearing - Connecting Rod to Crank Shaft 03 90 - N0101 - 01 8 Purchase Parts Engine Ass'y

100 Engine Assembly

A Assembly of Crank Drive Subsystem Components to Engine 03 00 - N0101 - 01 NA Diff.

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$0.00 - $ - $ $ - $ - - $ - $ 

($10.61) $ - - $ $ (10.61) $ (0.74) (0.07) $ (0.85

$ 

$1.19 - $ 1.11 $ $ 2.30 $ 0.15 0.01 $ 0.14 $ 

($0.36) $ 3.04 0.39 $ $ 3.07 $ 0.22 0.34 $ 0.20 $ 

$5.69 - $ - $ $ 5.69 $ - - $ - $ 

$ (4.09) $ 4.15 0.39 $ $ 0.46 $ 0.28 $ (0.51

(0.37) $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup 

INCREMENTAL COST TO UPGRADE TO NEW 

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V 

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Manufacturing 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-03, 4 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

04 Counter Balance Subsystem

01 Moved Parts

A Balance Shaft Subassembly ( Part of Oil Pump Assembly) 04 01 B0101 01 1 Full - $ - $ - $ $ - $ - - $ - $ - $ 

100

A Assembly of Balance Shaft Assembly to Engine 04 00 B0101 01 NA Full - $ - $ - $ $ - $ - - $ - $ - $ 

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

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101) GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number Markup 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-04, 5 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

04 Counter Balance Subsystem

01 Moved Parts

A Balance Shaft Subassembly ( Part of Oil Pump Assembly) 04 01 B0101 01 1 Full

100

A Assembly of Balance Shaft Assembly to Engine 04 00 B0101 01 NA Full

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

$ 5.83 8.53 $ 10.65 $ $ 25.01 $ 3.22 0.82 $ 2.98 $ 0.92 $ $ 0.39 1.83 $ 0.71 $ $ 2.93 $ - - $ - $ - $ 

$ 6.22 10.37 $ 11.36 $ $ 27.94 $ 3.22 0.82 $ 2.98 $ 0.92 $ 

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-04, 6 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

04 Counter Balance Subsystem

01 Moved Parts

A Balance Shaft Subassembly ( Part of Oil Pump Assembly) 04 01 B0101 01 1 Full

100

A Assembly of Balance Shaft Assembly to Engine 04 00 B0101 01 NA Full

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

($8.53) (5.83) $ (10.65) $ $ (25.01) $ (3.22) (0.82) $ (2.98

$ 

($1.83) (0.39) $ (0.71) $ $ (2.93) $ - - $ - $ 

$ (6.22) (10.37) $ (11.36) $ $ (27.94) $ (3.22) (0.82) $ (2.98

$ 

Markup 

INCREMENTAL COST TO UPGRADE TO NEW 

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V 

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-04, 7 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

05 Cylinder Block Subsystem

01 Cylinder Block

A Cylinder Block Assembly - Machined w. Studs, Plugs, etc. 05 01 - N0101 - 01 1 Diff. $ (7.96) $ 0.99 0.07 $ $ (6.90) $ (0.56) (0.41) $ (0.62) $ $ - 

A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 05 01 - N0101 - 02 1 PIA

A1.1 Cylinder Block Subassembly - Cast 05 01 - N0101 - 03 1 PIA

A1.1.1Cylinder Liners - Cast Iron 05 01 - N0101 - 04 1 PIA

03 Bedplates Diff. $ (4.36) $ - - $ $ (4.36) $ (0.34) (0.25) $ (0.38) $ $ - 

A Bed Plate Assembly - Machined w. Studs, Plugs, etc. 05 03 - N0101 - 01 1

A1 Bed Plate Assembly - Machined w/o. Studs, Plugs, etc. 05 03 - N0101 - 02 1 PIA

A1.1 Bed Plate Subassembly - Cast 05 03 - N0101 - 02 1 PIA

A1.1.1Bearing Cap - Bolt Through - Insert, Steel 05 03 - N0101 - 03 5 PIA

04 Piston Cooling

A Squirter - Oil, Piston Cooler 05 04 - N0101 - 01 4 Full 2.60 $ 0.64 $ 3.62 $ $ 6.86 $ 0.87 0.04 $ 0.58 $ - $ 

B Bolt - Piston Cooler Valve/Retainer 05 04 - N0101 - 02 4 (Grouped w. A)

90 Bearing Elements: Crankshaft bearing shells (Costs shown per engine bearing set)

A Bearing - Crankshaft, Block 1/2 Bearing (Top w. Lub. Pass.)05 90 - N0101 - 01 1 5pcs/set Diff. 2.13 $ - $ - $ $ 2.13 $ - - $ - $ - $ 

B Bearing/Shim - Crankshaft Thrust 05 90 - N0101 - 02 1 2pcs/set (Grouped w. A)

C Bearing - Crankshaft, Block 1/2 Bearing (Bottom) 05 90 - N0101 - 03 1 5 pcs/set (Grouped w. A)

100 Engine Assembly

A Assembly of Additional Cylinder Block Components Diff. - $ 0.65 $ 1.17 $ $ 1.82 $ 0.86 0.09 $ 0.99 $ - $ 

$ (7.59) $ 5.78 1.36 $ $ (0.46) $ (0.53) $ 0.56 0.83 $ - $ 

NOTES:

1.

Markup

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File: SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-05, 8 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

05 Cylinder Block Subsystem

01 Cylinder Block

A Cylinder Block Assembly - Machined w. Studs, Plugs, etc. 05 01 - N0101 - 01 1 Diff.

A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 05 01 - N0101 - 02 1 PIA

A1.1 Cylinder Block Subassembly - Cast 05 01 - N0101 - 03 1 PIA

A1.1.1Cylinder Liners - Cast Iron 05 01 - N0101 - 04 1 PIA

03 Bedplates Diff.

A Bed Plate Assembly - Machined w. Studs, Plugs, etc. 05 03 - N0101 - 01 1

A1 Bed Plate Assembly - Machined w/o. Studs, Plugs, etc. 05 03 - N0101 - 02 1 PIA

A1.1 Bed Plate Subassembly - Cast 05 03 - N0101 - 02 1 PIA

A1.1.1Bearing Cap - Bolt Through - Insert, Steel 05 03 - N0101 - 03 5 PIA

04 Piston Cooling

A Squirter - Oil, Piston Cooler 05 04 - N0101 - 01 4 Full

B Bolt - Piston Cooler Valve/Retainer 05 04 - N0101 - 02 4 (Grouped w. A)

90 Bearing Elements: Crankshaft bearing shells (Costs shown per engine bearing set)

A Bearing - Crankshaft, Block 1/2 Bearing (Top w. Lub. Pass.)05 90 - N0101 - 01 1 5pcs/set Diff.

B Bearing/Shim - Crankshaft Thrust 05 90 - N0101 - 02 1 2pcs/set (Grouped w. A)

C Bearing - Crankshaft, Block 1/2 Bearing (Bottom) 05 90 - N0101 - 03 1 5 pcs/set (Grouped w. A)

100 Engine Assembly

A Assembly of Additional Cylinder Block Components Diff.

NOTES:

1.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Manufacturing 

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

File: SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-05, 9 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

05 Cylinder Block Subsystem

01 Cylinder Block

A Cylinder Block Assembly - Machined w. Studs, Plugs, etc. 05 01 - N0101 - 01 1 Diff.

A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 05 01 - N0101 - 02 1 PIA

A1.1 Cylinder Block Subassembly - Cast 05 01 - N0101 - 03 1 PIA

A1.1.1Cylinder Liners - Cast Iron 05 01 - N0101 - 04 1 PIA

03 Bedplates Diff.

A Bed Plate Assembly - Machined w. Studs, Plugs, etc. 05 03 - N0101 - 01 1

A1 Bed Plate Assembly - Machined w/o. Studs, Plugs, etc. 05 03 - N0101 - 02 1 PIA

A1.1 Bed Plate Subassembly - Cast 05 03 - N0101 - 02 1 PIA

A1.1.1Bearing Cap - Bolt Through - Insert, Steel 05 03 - N0101 - 03 5 PIA

04 Piston Cooling

A Squirter - Oil, Piston Cooler 05 04 - N0101 - 01 4 Full

B Bolt - Piston Cooler Valve/Retainer 05 04 - N0101 - 02 4 (Grouped w. A)

90 Bearing Elements: Crankshaft bearing shells (Costs shown per engine bearing set)

A Bearing - Crankshaft, Block 1/2 Bearing (Top w. Lub. Pass.)05 90 - N0101 - 01 1 5pcs/set Diff.

B Bearing/Shim - Crankshaft Thrust 05 90 - N0101 - 02 1 2pcs/set (Grouped w. A)

C Bearing - Crankshaft, Block 1/2 Bearing (Bottom) 05 90 - N0101 - 03 1 5 pcs/set (Grouped w. A)

100 Engine Assembly

A Assembly of Additional Cylinder Block Components Diff.

NOTES:

1.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

($7.96) $ 0.99 0.07 $ $ (6.90) $ (0.56) (0.41) $ (0.62

$ 

($4.36) $ - - $ $ (4.36) $ (0.34) (0.25) $ (0.38

$ 

$0.00 - $ - $ $ - $ - - $ - $ $2.60 0.64 $ 3.62 $ $ 6.86 $ 0.87 0.04 $ 0.58 $ 

`

$2.13 - $ - $ $ 2.13 $ - - $ - $ 

$0.00 0.65 $ 1.17 $ $ 1.82 $ 0.86 0.09 $ 0.99 $ 

$ (7.59) $ 5.78 1.36 $ $ (0.46) $ (0.53) $ 0.56 0.83 $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

INCREMENTAL COST TO UPGRADE TO NEW 

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V 

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Manufacturing Markup

File: SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-05, 10 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

R&D

06 Cylinder Head Subsystem

01 Cylinder Head

A Cylinder Head Assembly - Machined w. Studs, Valves, etc. 06 01 - N0101 - 01 1 Diff $ (0.83) $ 6.11 0.63 $ $ 5.91 $ 0.54 1.79 $ 0.61 $ - $ 

A1 Cylinder Head - Machined w/o. Studs, Valves, etc. 06 01 - N0101 - 02 1 PIA Head Assembly

A1.1 Cylinder Head Subassembly - Cast 06 01 - N0101 - 03 1 PIA Head Assembly

02 Valve Guides. Valve Seats

C Seat - Intake Valve 06 02 - N0101 - 03 8 Diff $ - 0.34 $ - $ $ 0.34 $ - - $ - $ - $ 

D Seat - Exhaust Valve 06 02 - N0101 - 04 8 (Grouped w. C)

06 Camshaft Bearing Housing 

C Cap, Head (Fuel Pump & Vacuum Mount) 06 06 - N0101 - 03 1 Full $ 0.18 0.67 $ 0.83 $ $ 1.69 $ 0.11 0.01 $ 0.10 $ 0.04 $ 

80 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

Boltings & Screws General

A Bolt - Cap Bearing, Camshaft 06 80 - N0101 - 01 4 PIA Engine Assembly

Dowel Pins/Plugs/Studs - Cylinder Head

A Bolt - Manifold, Exhaust 06 80 - N0101 - 10 10 PIA Engine Assembly

85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

A Gasket - Cylinder Head to Block 06 85 - N0101 - 01 1 Diff. $ - 1.46 $ - $ $ 1.46 $ - - $ - $ - $ 

100 Engine Assembly

A Assembly of Additional/Revised Cylinder Head Components 1 Diff. $ - 3.92 $ - $ $ 3.92 $ - - $ - $ - $ 

$ 0.81 5.57 $ 6.94 $ $ 13.32 $ 0.65 1.80 $ 0.71 $ 0.04 $ 

NOTES:

1.

Markup

Subassembly 

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-06, 11 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

06 Cylinder Head Subsystem

01 Cylinder Head

A Cylinder Head Assembly - Machined w. Studs, Valves, etc. 06 01 - N0101 - 01 1 Diff

A1 Cylinder Head - Machined w/o. Studs, Valves, etc. 06 01 - N0101 - 02 1 PIA Head Assembly

A1.1 Cylinder Head Subassembly - Cast 06 01 - N0101 - 03 1 PIA Head Assembly

02 Valve Guides. Valve Seats

C Seat - Intake Valve 06 02 - N0101 - 03 8 Diff

D Seat - Exhaust Valve 06 02 - N0101 - 04 8 (Grouped w. C)

06 Camshaft Bearing Housing 

C Cap, Head (Fuel Pump & Vacuum Mount) 06 06 - N0101 - 03 1 Full

80 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

Boltings & Screws General

A Bolt - Cap Bearing, Camshaft 06 80 - N0101 - 01 4 PIA Engine Assembly

Dowel Pins/Plugs/Studs - Cylinder Head

A Bolt - Manifold, Exhaust 06 80 - N0101 - 10 10 PIA Engine Assembly

85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

A Gasket - Cylinder Head to Block 06 85 - N0101 - 01 1 Diff.

100 Engine Assembly

A Assembly of Additional/Revised Cylinder Head Components 1 Diff.

NOTES:

1.

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Manufacturing 

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-06, 12 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

06 Cylinder Head Subsystem

01 Cylinder Head

A Cylinder Head Assembly - Machined w. Studs, Valves, etc. 06 01 - N0101 - 01 1 Diff

A1 Cylinder Head - Machined w/o. Studs, Valves, etc. 06 01 - N0101 - 02 1 PIA Head Assembly

A1.1 Cylinder Head Subassembly - Cast 06 01 - N0101 - 03 1 PIA Head Assembly

02 Valve Guides. Valve Seats

C Seat - Intake Valve 06 02 - N0101 - 03 8 Diff

D Seat - Exhaust Valve 06 02 - N0101 - 04 8 (Grouped w. C)

06 Camshaft Bearing Housing 

C Cap, Head (Fuel Pump & Vacuum Mount) 06 06 - N0101 - 03 1 Full

80 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

Boltings & Screws General

A Bolt - Cap Bearing, Camshaft 06 80 - N0101 - 01 4 PIA Engine Assembly

Dowel Pins/Plugs/Studs - Cylinder Head

A Bolt - Manifold, Exhaust 06 80 - N0101 - 10 10 PIA Engine Assembly

85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

A Gasket - Cylinder Head to Block 06 85 - N0101 - 01 1 Diff.

100 Engine Assembly

A Assembly of Additional/Revised Cylinder Head Components 1 Diff.

NOTES:

1.

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

($0.83) $ 6.11 0.63 $ $ 5.91 $ 0.54 1.79 $ 0.61 $ 

$0.34 - $ - $ $ 0.34 $ - - $ - $ $0.67 0.18 $ 0.83 $ $ 1.69 $ 0.11 0.01 $ 0.10 $ $1.46 - $ - $ $ 1.46 $ - - $ - $ $3.92 - $ - $ $ 3.92 $ - - $ - $ 

$ 0.81 5.57 $ 6.94 $ $ 13.32 $ 0.65 1.80 $ 0.71 $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NEW 

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V 

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-06, 13 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

07 Valve Train Subsystem

01 Inlet Valves

A Valve - Intake 07 01 - N0101 - 01 8 Diff. 8.66 $ - $ - $ $ 8.66 $ 0.61 0.06 $ 0.69 $ 0.35 $ 

02 Outlet Valves

A Valve - Exhaust 07 02 - N0101 - 01 8 Exhaust Valves grouped with Intake Valve Costs Diff.

06 Camshafts

A Camshaft Assembly - Intake Machined 07 06 - N0101 - 01 1 Diff. $ (0.26) $ - - $ $ (0.26) $ (0.02) (0.01) $ (0.02) $ (0.01

$ 

A1 Camshaft - Intake Machined 07 06 - N0101 - 02 1 PIA

B Camshaft Assembly - Exhaust Machined 07 06 - N0101 - 10 1 Exhaust Cam Shaft grouped with Intake Cam Shaft Costs Diff.

B1 Camshaft - Exhaust Machine 07 06 - N0101 - 11 1 PIA

100 Engine Assembly

A Engine Assembly Impact Mark-up affect only Diff. - $ - $ - $ $ - $ - - $ - $ - $ 

$8.40 - $ - $ $ 8.40 $ 0.59 0.05 $ 0.68 $ 0.34 $ 

NOTES:

1.

Markup

Subassembly 

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-07, 14 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

07 Valve Train Subsystem

01 Inlet Valves

A Valve - Intake 07 01 - N0101 - 01 8 Diff.

02 Outlet Valves

A Valve - Exhaust 07 02 - N0101 - 01 8 Exhaust Valves grouped with Intake Valve Costs Diff.

06 Camshafts

A Camshaft Assembly - Intake Machined 07 06 - N0101 - 01 1 Diff.

A1 Camshaft - Intake Machined 07 06 - N0101 - 02 1 PIA

B Camshaft Assembly - Exhaust Machined 07 06 - N0101 - 10 1 Exhaust Cam Shaft grouped with Intake Cam Shaft Costs Diff.

B1 Camshaft - Exhaust Machine 07 06 - N0101 - 11 1 PIA

100 Engine Assembly

A Engine Assembly Impact Mark-up affect only Diff.

NOTES:

1.

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

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

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

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

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Manufacturing 

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-07, 15 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

07 Valve Train Subsystem

01 Inlet Valves

A Valve - Intake 07 01 - N0101 - 01 8 Diff.

02 Outlet Valves

A Valve - Exhaust 07 02 - N0101 - 01 8 Exhaust Valves grouped with Intake Valve Costs Diff.

06 Camshafts

A Camshaft Assembly - Intake Machined 07 06 - N0101 - 01 1 Diff.

A1 Camshaft - Intake Machined 07 06 - N0101 - 02 1 PIA

B Camshaft Assembly - Exhaust Machined 07 06 - N0101 - 10 1 Exhaust Cam Shaft grouped with Intake Cam Shaft Costs Diff.

B1 Camshaft - Exhaust Machine 07 06 - N0101 - 11 1 PIA

100 Engine Assembly

A Engine Assembly Impact Mark-up affect only Diff.

NOTES:

1.

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$8.66 - $ - $ $ 8.66 $ 0.61 0.06 $ 0.69 $ 

($0.26) $ - - $ $ (0.26) $ (0.02) (0.01) $ (0.02

$ 

$0.00 - $ - $ $ - $ - - $ - $ 

$ - 8.40 $ - $ $ 8.40 $ 0.59 0.05 $ 0.68 $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NEW 

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V 

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-07, 16 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

08 Timing Drive Subsystem

01 Timing Wheels (Sprockets)

A Sprocket - Crankshaft, Timing Drive 08 01 - N0101 - 01 1 Smart Sprocket Mod 1.60 $ - $ - $ $ 1.60 $ - - $ - $ - $ 

100 Engine Assembly 

A Timing Drive Impact to engine assembly NA $ - - $ - $ $ - $ - - $ - $ - $ 

$1.60 - $ - $ $ 1.60 $ - - $ - $ - $ 

NOTES:

1.

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

Markup

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

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-08, 17 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

08 Timing Drive Subsystem

01 Timing Wheels (Sprockets)

A Sprocket - Crankshaft, Timing Drive 08 01 - N0101 - 01 1 Smart Sprocket Mod

100 Engine Assembly 

A Timing Drive Impact to engine assembly NA

NOTES:

1.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-08, 18 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

08 Timing Drive Subsystem

01 Timing Wheels (Sprockets)

A Sprocket - Crankshaft, Timing Drive 08 01 - N0101 - 01 1 Smart Sprocket Mod

100 Engine Assembly 

A Timing Drive Impact to engine assembly NA

NOTES:

1.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$1.60 - $ - $ $ 1.60 $ - - $ - $ 

$0.00 - $ - $ $ - $ - - $ - $ 

$ - 1.60 $ - $ $ 1.60 $ - - $ - $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

INCREMENTAL COST TO UPGRADE TO NEW 

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V 

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Manufacturing Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-08, 19 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

R&D

10 Intake Subsystem

01 Intake Manifolds

A Manifold Assembly - Intake 10 01 - N0101 - 01 1 Diff. $ (0.01) (10.66) $ (0.10) $ $ (10.78) $ (0.70) (0.05) $ (0.65) $ (0.2

$ 

100 Engine Assembly 

A Timing Drive Impact to engine assembly 10 00 N0101 001 1 NA $ - - $ - $ $ - $ - - $ - $ - $ 

($10.66) (0.01) $ (0.10) $ $ (10.78) $ (0.70) (0.05) $ (0.65) $ (0.2

$ 

NOTES:

1.

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

Markup

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-10, 20 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

10 Intake Subsystem

01 Intake Manifolds

A Manifold Assembly - Intake 10 01 - N0101 - 01 1 Diff.

100 Engine Assembly 

A Timing Drive Impact to engine assembly 10 00 N0101 001 1 NA

NOTES:

1.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-10, 21 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

10 Intake Subsystem

01 Intake Manifolds

A Manifold Assembly - Intake 10 01 - N0101 - 01 1 Diff.

100 Engine Assembly 

A Timing Drive Impact to engine assembly 10 00 N0101 001 1 NA

NOTES:

1.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

($10.66) (0.01) $ (0.10) $ $ (10.78) $ (0.70) (0.05) $ (0.65

$ 

$0.00 - $ - $ $ - $ - - $ - $ 

$ (0.01) (10.66) $ (0.10) $ $ (10.78) $ (0.70) (0.05) $ (0.65

$ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NE

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-10, 22 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

11 Fuel Induction Subsystem

01 Fuel Rails

A Fuel Rail w. High Pressure Sensor Assembly 11 01 - N0101 - 01 1 Full 11.09 $ 1.81 $ 5.70 $ $ 18.59 $ 1.12 0.06 $ 0.74 $ 0.19 $ 

A1 Fuel Rail - High Pressure 11 01 - N0101 - 02 1 PIA Fuel Rail AssemblyA2 Sensor - Fuel, High Pressure 11 01 - N0101 - 03 1 PIA Fuel Rail Assembly

04 Fuel Injectors

A Fuel Injector Assembly - Solenoid, 7 Hole 11 04 - N0101 - 01 4 Full $8.63 $5.88 $25.74 $ 40.25 $ 4.72 0.43 $ 5.03 $ 2.01 $ 

07 Fuel Injection Pumps

A 11 07 - N0101 - 01 1 Full $16.99 $8.24 $28.32 $ 53.55 $ 6.36 0.73 $ 6.40 $ 2.46 $ 

70 Pipes, Hoses: Low Pressure, High Pressure

A Pipe Assembly - Fuel, High Pressure, Pump to Rail 11 70 - N0101 - 01 1 Full $0.39 $0.34 $1.06 $ 1.80 $ 0.11 0.01 $ 0.07 $ 0.02 $ 

80 Bolting

A Bolt - Fuel Rail 11 80 - N0101 - 01 4 PIA Engine Assembly Diff.

B Bolt - Fuel Pump 11 80 - N0101 - 02 3 PIA Engine Assembly FullC Retainer - Fuel Injector 11 80 - N0101 - 03 4 PIA Injector FullD Washer, Retainer - Fuel Injector 11 80 - N0101 - 04 4 PIA Injector FullE O-ring Retainer, Fuel Injector 11 80 - N0101 - 05 4 PIA Injector FullF Spacer - Retainer, Fuel Injector 11 80 - N0101 - 06 4 PIA Injector Full

85 Sealing Elements

A Seal - High Pressure Fuel Pump to Cylinder Head 11 85 - N0101 - 01 1 PIA Fuel Pump Full

100 Engine Assembly 

A Fuel Induction impact to engine assembly Diff. 0.15 $ 1.13 $ 2.04 $ $ 3.33 $ - - $ - $ - $ 

$37.24 17.41 $ 62.87 $ $ 117.52 $ 12.30 1.23 $ 12.25 $ 4.67 $ 

NOTES:

1.

Markup

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

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

Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off Intake 

Cam)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-11, 23 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

11 Fuel Induction Subsystem

01 Fuel Rails

A Fuel Rail w. High Pressure Sensor Assembly 11 01 - N0101 - 01 1 Full

A1 Fuel Rail - High Pressure 11 01 - N0101 - 02 1 PIA Fuel Rail Assembly

A2 Sensor - Fuel, High Pressure 11 01 - N0101 - 03 1 PIA Fuel Rail Assembly

04 Fuel Injectors

A Fuel Injector Assembly - Solenoid, 7 Hole 11 04 - N0101 - 01 4 Full

07 Fuel Injection Pumps

A 11 07 - N0101 - 01 1 Full

70 Pipes, Hoses: Low Pressure, High Pressure

A Pipe Assembly - Fuel, High Pressure, Pump to Rail 11 70 - N0101 - 01 1 Full

80 Bolting

A Bolt - Fuel Rail 11 80 - N0101 - 01 4 PIA Engine Assembly Diff.

B Bolt - Fuel Pump 11 80 - N0101 - 02 3 PIA Engine Assembly FullC Retainer - Fuel Injector 11 80 - N0101 - 03 4 PIA Injector FullD Washer, Retainer - Fuel Injector 11 80 - N0101 - 04 4 PIA Injector FullE O-ring Retainer, Fuel Injector 11 80 - N0101 - 05 4 PIA Injector FullF Spacer - Retainer, Fuel Injector 11 80 - N0101 - 06 4 PIA Injector Full

85 Sealing Elements

A Seal - High Pressure Fuel Pump to Cylinder Head 11 85 - N0101 - 01 1 PIA Fuel Pump Full

100 Engine Assembly 

A Fuel Induction impact to engine assembly Diff.

NOTES:

1.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off Intake 

Cam)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

R&D

$ 1.46 1.36 $ 2.35 $ $ 5.18 $ 0.31 0.02 $ 0.21 $ 0.05 $ 

$ 4.15 4.13 $ 19.46 $ $ 27.74 $ 2.79 0.26 $ 2.98 $ 1.26 $ 

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

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

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

$ 5.61 5.49 $ 21.81 $ $ 32.91 $ 3.10 0.27 $ 3.19 $ 1.3

$ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Manufacturing 

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-11, 24 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

11 Fuel Induction Subsystem

01 Fuel Rails

A Fuel Rail w. High Pressure Sensor Assembly 11 01 - N0101 - 01 1 Full

A1 Fuel Rail - High Pressure 11 01 - N0101 - 02 1 PIA Fuel Rail Assembly

A2 Sensor - Fuel, High Pressure 11 01 - N0101 - 03 1 PIA Fuel Rail Assembly

04 Fuel Injectors

A Fuel Injector Assembly - Solenoid, 7 Hole 11 04 - N0101 - 01 4 Full

07 Fuel Injection Pumps

A 11 07 - N0101 - 01 1 Full

70 Pipes, Hoses: Low Pressure, High Pressure

A Pipe Assembly - Fuel, High Pressure, Pump to Rail 11 70 - N0101 - 01 1 Full

80 Bolting

A Bolt - Fuel Rail 11 80 - N0101 - 01 4 PIA Engine Assembly Diff.

B Bolt - Fuel Pump 11 80 - N0101 - 02 3 PIA Engine Assembly FullC Retainer - Fuel Injector 11 80 - N0101 - 03 4 PIA Injector FullD Washer, Retainer - Fuel Injector 11 80 - N0101 - 04 4 PIA Injector FullE O-ring Retainer, Fuel Injector 11 80 - N0101 - 05 4 PIA Injector FullF Spacer - Retainer, Fuel Injector 11 80 - N0101 - 06 4 PIA Injector Full

85 Sealing Elements

A Seal - High Pressure Fuel Pump to Cylinder Head 11 85 - N0101 - 01 1 PIA Fuel Pump Full

100 Engine Assembly 

A Fuel Induction impact to engine assembly Diff.

NOTES:

1.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off Intake 

Cam)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$9.72 0.35 $ 3.35 $ $ 13.42 $ 0.81 0.04 $ 0.54 $ 

$4.50 1.74 $ 6.28 $ $ 12.51 $ 1.93 0.18 $ 2.05 $ 

$16.99 8.24 $ 28.32 $ $ 53.55 $ 6.36 0.73 $ 6.40 $ 

$0.39 0.34 $ 1.06 $ $ 1.80 $ 0.11 0.01 $ 0.07 $ $0.15 1.13 $ 2.04 $ $ 3.33 $ - - $ - $ 

$ 11.80 31.75 $ 41.05 $ $ 84.60 $ 9.20 0.95 $ 9.06 $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

INCREMENTAL COST TO UPGRADE TO NE

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16

(Study Case# N010

Markup

Manufacturing 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-11, 25 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

12 Exhaust Subsystem

01 Exhaust Manifold

A Manifold - Exhaust, Dual Wall 12 01 - N0101 - 01 1 Diff. 22.64 $ 0.03 $ 3.03 $ $ 25.70 $ 1.85 2.97 $ 1.71 $ 0.71 $ 

75 Brackets

B Bracket Subassembly- Heat Shield, Top, Turbo 12 75 - N0101 - 02 1 Diff. $ 0.08 1.77 $ 0.07 $ $ 1.91 $ 0.11 0.01 $ 0.08 $ - $ 

80 Bolting

A Nut- Manifold Exhaust to Cylinder Head 12 80 - N0101 - 01 10 PIA Engine Assembly

F Nut - Turbo to C.C. Catalytic Converter 12 80 - N0101 - 06 3 PIA Engine Assembly

G Nut - Exhaust Manifold to Turbo 12 80 - N0101 - 07 4 Covered in Air Induction

85 Sealing Elements

A Gasket Assembly - Exhaust Manifold 12 85 - B0101 - 01 1 Diff. $ - 0.95 $ - $ $ 0.95 $ - - $ - $ - $ 

Bracket Subassembly - Exhaust Manifold w. Integrated Gasket 12 75 - N0101 - 01 1 Gasket integrated into heat shield mounting bracket.

100 Vehicle Operations or Engine Assembly

A Assembly of Exhaust System Components to Engine 12 00 - N0101 - 01 Component Cost Only Diff. $ - 1.89 $ - $ $ 1.89 $ - - $ - $ - $ 

$27.24 0.11 $ 3.09 $ $ 30.45 $ 1.97 2.97 $ 1.79 $ 0.71 $ 

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101) GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Markup

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-12, 26 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

12 Exhaust Subsystem

01 Exhaust Manifold

A Manifold - Exhaust, Dual Wall 12 01 - N0101 - 01 1 Diff.

75 Brackets

B Bracket Subassembly- Heat Shield, Top, Turbo 12 75 - N0101 - 02 1 Diff.

80 Bolting

A Nut- Manifold Exhaust to Cylinder Head 12 80 - N0101 - 01 10 PIA Engine Assembly

F Nut - Turbo to C.C. Catalytic Converter 12 80 - N0101 - 06 3 PIA Engine Assembly

G Nut - Exhaust Manifold to Turbo 12 80 - N0101 - 07 4 Covered in Air Induction

85 Sealing Elements

A Gasket Assembly - Exhaust Manifold 12 85 - B0101 - 01 1 Diff.

Bracket Subassembly - Exhaust Manifold w. Integrated Gasket 12 75 - N0101 - 01 1 Gasket integrated into heat shield mounting bracket.

100 Vehicle Operations or Engine Assembly

A Assembly of Exhaust System Components to Engine 12 00 - N0101 - 01 Component Cost Only Diff.

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

R&D

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

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

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

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

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

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-12, 27 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

12 Exhaust Subsystem

01 Exhaust Manifold

A Manifold - Exhaust, Dual Wall 12 01 - N0101 - 01 1 Diff.

75 Brackets

B Bracket Subassembly- Heat Shield, Top, Turbo 12 75 - N0101 - 02 1 Diff.

80 Bolting

A Nut- Manifold Exhaust to Cylinder Head 12 80 - N0101 - 01 10 PIA Engine Assembly

F Nut - Turbo to C.C. Catalytic Converter 12 80 - N0101 - 06 3 PIA Engine Assembly

G Nut - Exhaust Manifold to Turbo 12 80 - N0101 - 07 4 Covered in Air Induction

85 Sealing Elements

A Gasket Assembly - Exhaust Manifold 12 85 - B0101 - 01 1 Diff.

Bracket Subassembly - Exhaust Manifold w. Integrated Gasket 12 75 - N0101 - 01 1 Gasket integrated into heat shield mounting bracket.

100 Vehicle Operations or Engine Assembly

A Assembly of Exhaust System Components to Engine 12 00 - N0101 - 01 Component Cost Only Diff.

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$22.64 0.03 $ 3.03 $ $ 25.70 $ 1.85 2.97 $ 1.7

$ 

$1.77 0.08 $ 0.07 $ $ 1.91 $ 0.11 0.01 $ 0.08 $ $0.95 - $ - $ $ 0.95 $ - - $ - $ $1.89 - $ - $ $ 1.89 $ - - $ - $ 

$ 0.11 27.24 $ 3.09 $ $ 30.45 $ 1.97 2.97 $ 1.79 $ 

Markup

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

INCREMENTAL COST TO UPGRADE TO NE

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16

(Study Case# N010

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-12, 28 of 46 
SUBSYTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

13 Lubrication Subsystem (e.g.Oil Pans, Sumps)

02 Oil Pumps

A Oil Pump Assembly 13 02 - N0101 - 01 1 1 Diff. 3.08 $ - $ - $ $ 3.08 $ 0.22 0.02 $ 0.25 $ 0.12 $ 

06 Oil Filter

A Filter Cooler Assembly - Oil (Includes Seals) 13 06 - N0101 - 01 1 1 Diff. $2.93 $2.23 $5.31 $ 10.48 $ 1.44 0.10 $ 1.21 $ 0.38 $ 

70 Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure, Low Pressure.

A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 13 70 - N0101 - 01 1

(Shipped PIA to Filter/Cooler Assembly, although showing cost broke out separately)

1 Full $1.27 $0.80 $1.59 $ 3.66 $ 0.23 0.01 $ 0.16 $ - $ 

B Tube Assembly - Oil, Turbo to Engine Block (Piston Squirter's) 13 70 - N0101 - 02 1 1 Full $0.42 $0.81 $2.20 $ 3.43 $ 0.24 0.01 $ 0.16 $ - $ 

80 Boltings & Clamps

C Bolt - Filter Cooler Assembly 13 80 - N0101 - 03 4 PIA to Engine Assembly

D Bolt - Tube Assembly , Oil, Turbo Inlet 13 80 - N0101 - 09 1 PIA to Engine AssemblyE Clamp - Tube Assembly, Oil, Cooler/Filter Outlet 13 80 - N0101 - 05 1 PIA Tube Assembly-Oil, ...F Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet 13 80 - N0101 - 06 2 PIA to Engine Assembly

85 Sealing Elements: Oil Pan Gasket,...

C Seal - Tube Assembly, Oil, Turbo Inlet 13 85 - N0101 - 03 1 PIA Tube Assembly-Oil, ...

D Compression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet 13 85 - N0101 - 04 4 PIA Tube Assembly-Oil, ...

99 Miscellaneous

F Oil - Synthetic 13 99 - N0101 - 08 1 1 Diff. $4.00 $0.00 $0.00 $ 4.00 $ - - $ - $ - $ 

100 Engine Assembly

A Assemble Additional or Modified Lubrication Subsystem Parts to Engine 1 Diff. $0.93 $1.46 $2.63 $ 5.02 $ - - $ - $ - $ 

$12.63 5.30 $ 11.74 $ $ 29.67 $ 2.13 0.14 $ 1.78 $ 0.51 $ 

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

Markup

Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-13, 29 of 46 
SUBSYTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

13 Lubrication Subsystem (e.g.Oil Pans, Sumps)

02 Oil Pumps

A Oil Pump Assembly 13 02 - N0101 - 01 1 1 Diff.

06 Oil Filter

A Filter Cooler Assembly - Oil (Includes Seals) 13 06 - N0101 - 01 1 1 Diff.

70 Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure, Low Pressure.

A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 13 70 - N0101 - 01 1

(Shipped PIA to Filter/Cooler Assembly, although showing cost broke out separately)

1 Full

B Tube Assembly - Oil, Turbo to Engine Block (Piston Squirter's) 13 70 - N0101 - 02 1 1 Full

80 Boltings & Clamps

C Bolt - Filter Cooler Assembly 13 80 - N0101 - 03 4 PIA to Engine Assembly

D Bolt - Tube Assembly , Oil, Turbo Inlet 13 80 - N0101 - 09 1 PIA to Engine AssemblyE Clamp - Tube Assembly, Oil, Cooler/Filter Outlet 13 80 - N0101 - 05 1 PIA Tube Assembly-Oil, ...F Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet 13 80 - N0101 - 06 2 PIA to Engine Assembly

85 Sealing Elements: Oil Pan Gasket,...

C Seal - Tube Assembly, Oil, Turbo Inlet 13 85 - N0101 - 03 1 PIA Tube Assembly-Oil, ...

D Compression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet 13 85 - N0101 - 04 4 PIA Tube Assembly-Oil, ...

99 Miscellaneous

F Oil - Synthetic 13 99 - N0101 - 08 1 1 Diff.

100 Engine Assembly

A Assemble Additional or Modified Lubrication Subsystem Parts to Engine 1 Diff.

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

R&D

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

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

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

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

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

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

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

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Manufacturing 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-13, 30 of 46 
SUBSYTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

13 Lubrication Subsystem (e.g.Oil Pans, Sumps)

02 Oil Pumps

A Oil Pump Assembly 13 02 - N0101 - 01 1 1 Diff.

06 Oil Filter

A Filter Cooler Assembly - Oil (Includes Seals) 13 06 - N0101 - 01 1 1 Diff.

70 Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure, Low Pressure.

A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 13 70 - N0101 - 01 1

(Shipped PIA to Filter/Cooler Assembly, although showing cost broke out separately)

1 Full

B Tube Assembly - Oil, Turbo to Engine Block (Piston Squirter's) 13 70 - N0101 - 02 1 1 Full

80 Boltings & Clamps

C Bolt - Filter Cooler Assembly 13 80 - N0101 - 03 4 PIA to Engine Assembly

D Bolt - Tube Assembly , Oil, Turbo Inlet 13 80 - N0101 - 09 1 PIA to Engine AssemblyE Clamp - Tube Assembly, Oil, Cooler/Filter Outlet 13 80 - N0101 - 05 1 PIA Tube Assembly-Oil, ...F Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet 13 80 - N0101 - 06 2 PIA to Engine Assembly

85 Sealing Elements: Oil Pan Gasket,...

C Seal - Tube Assembly, Oil, Turbo Inlet 13 85 - N0101 - 03 1 PIA Tube Assembly-Oil, ...

D Compression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet 13 85 - N0101 - 04 4 PIA Tube Assembly-Oil, ...

99 Miscellaneous

F Oil - Synthetic 13 99 - N0101 - 08 1 1 Diff.

100 Engine Assembly

A Assemble Additional or Modified Lubrication Subsystem Parts to Engine 1 Diff.

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$3.08 - $ - $ $ 3.08 $ 0.22 0.02 $ 0.25 $ 

$2.93 2.23 $ 5.31 $ $ 10.48 $ 1.44 0.10 $ 1.2

$ 

$1.27 0.80 $ 1.59 $ $ 3.66 $ 0.23 0.01 $ 0.16 $ 

$ 0.81 0.42 $ 2.20 $ $ 3.43 $ 0.24 0.01 $ 0.16 $ $ - 4.00 $ - $ $ 4.00 $ - - $ - $ 

$0.93 1.46 $ 2.63 $ $ 5.02 $ - - $ - $ 

$ 5.30 12.63 $ 11.74 $ $ 29.67 $ 2.13 0.14 $ 1.78 $ 

Markup

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

INCREMENTAL COST TO UPGRADE TO NE

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16

(Study Case# N010

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-13, 31 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

14 Cooling Subsystem

01 Water Pumps

B Pump- Auxiliary Coolant, Electric 14 01 - N0101 - 02 1 Full 13.90 $ 1.63 $ 4.22 $ $ 19.75 $ 1.82 0.18 $ 2.07 $ 1.03 $ 

70 Pipes, Hoses, Ducting

B Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 14 70 - N0101 - 02 1 Full $ 1.10 1.02 $ 2.01 $ $ 4.13 $ 0.25 0.00 $ 0.17 $ - $ 

C Hose Assembly - Auxiliary Pump to Turbo 14 70 - N0101 - 03 1 Full $ 0.87 0.72 $ 1.85 $ $ 3.45 $ 0.21 0.01 $ 0.14 $ - $ 

D 14 70 - N0101 - 04 1 Full $ 0.59 0.85 $ 0.43 $ $ 1.88 $ 0.11 0.01 $ 0.08 $ - $ 

75 Brackets

A 14 75 - N0101 - 01 1 PIA to Aux. Pump

80 Boltings & Clamps

D 14 80 - N0101 - 04 1 PIA to Hose Assembly

E 14 80 - N0101 - 05 1 PIA to Engine Assembly

F 14 80 - N0101 - 06 2 PIA to Engine Assembly

G 14 80 - N0101 - 07 2 PIA to Engine Assembly

I 14 80 - N0101 - 09 1 PIA to Hose Assembly

J 14 80 - N0101 - 10 2 PIA to Hose Assembly

M 14 80 - N0101 - 13 4 PIA to Engine Assembly

100 Engine Assembly

A Mod $ 1.94 0.74 $ 3.50 $ $ 6.19 $ - - $ - $ - $ 

$17.24 6.14 $ 12.02 $ $ 35.40 $ 2.39 0.20 $ 2.45 $ 1.03 $ 

NOTES:

1.

Assembly Additional or Revised Cooling Subsystem parts to Engine

Clamp - Hose, Auxiliary Pump to Turbo Clamp - Hose, Oil Filter Cooler Assembly to Auxiliary 

Pump Washer Banjo Bolt - Hose Coolant Inlet & Outlet TurboClamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ ThermoBolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKT MountBolt-Hose, Inlet and Outlet @ Turbo Bolt - Auxiliary Pump to Oil Filter Cooler Bracket Assembly

Markup

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DO

(Study Case# N0101)

Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y

Hose Assembly - Oil Filer/Cooler Ass'y to AuxiliaryPump

Manufacturing 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-14, 32 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

14 Cooling Subsystem

01 Water Pumps

B Pump- Auxiliary Coolant, Electric 14 01 - N0101 - 02 1 Full

70 Pipes, Hoses, Ducting

B Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 14 70 - N0101 - 02 1 Full

C Hose Assembly - Auxiliary Pump to Turbo 14 70 - N0101 - 03 1 Full

D 14 70 - N0101 - 04 1 Full

75 Brackets

A 14 75 - N0101 - 01 1 PIA to Aux. Pump

80 Boltings & Clamps

D 14 80 - N0101 - 04 1 PIA to Hose Assembly

E 14 80 - N0101 - 05 1 PIA to Engine Assembly

F 14 80 - N0101 - 06 2 PIA to Engine Assembly

G 14 80 - N0101 - 07 2 PIA to Engine Assembly

I 14 80 - N0101 - 09 1 PIA to Hose Assembly

J 14 80 - N0101 - 10 2 PIA to Hose Assembly

M 14 80 - N0101 - 13 4 PIA to Engine Assembly

100 Engine Assembly

A Mod

NOTES:

1.

Assembly Additional or Revised Cooling Subsystem parts to Engine

Clamp - Hose, Auxiliary Pump to Turbo Clamp - Hose, Oil Filter Cooler Assembly to Auxiliary 

Pump Washer Banjo Bolt - Hose Coolant Inlet & Outlet TurboClamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ ThermoBolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKT MountBolt-Hose, Inlet and Outlet @ Turbo Bolt - Auxiliary Pump to Oil Filter Cooler Bracket Assembly

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y

Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary

Pump

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

R&D

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

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

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

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

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

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

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Manufacturing 

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V D

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-14, 33 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

14 Cooling Subsystem

01 Water Pumps

B Pump- Auxiliary Coolant, Electric 14 01 - N0101 - 02 1 Full

70 Pipes, Hoses, Ducting

B Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 14 70 - N0101 - 02 1 Full

C Hose Assembly - Auxiliary Pump to Turbo 14 70 - N0101 - 03 1 Full

D 14 70 - N0101 - 04 1 Full

75 Brackets

A 14 75 - N0101 - 01 1 PIA to Aux. Pump

80 Boltings & Clamps

D 14 80 - N0101 - 04 1 PIA to Hose Assembly

E 14 80 - N0101 - 05 1 PIA to Engine Assembly

F 14 80 - N0101 - 06 2 PIA to Engine Assembly

G 14 80 - N0101 - 07 2 PIA to Engine Assembly

I 14 80 - N0101 - 09 1 PIA to Hose Assembly

J 14 80 - N0101 - 10 2 PIA to Hose Assembly

M 14 80 - N0101 - 13 4 PIA to Engine Assembly

100 Engine Assembly

A Mod

NOTES:

1.

Assembly Additional or Revised Cooling Subsystem parts to Engine

Clamp - Hose, Auxiliary Pump to Turbo Clamp - Hose, Oil Filter Cooler Assembly to Auxiliary 

Pump Washer Banjo Bolt - Hose Coolant Inlet & Outlet TurboClamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ ThermoBolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKT MountBolt-Hose, Inlet and Outlet @ Turbo Bolt - Auxiliary Pump to Oil Filter Cooler Bracket Assembly

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

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

Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y

Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary

Pump

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$13.90 1.63 $ 4.22 $ $ 19.75 $ 1.82 0.18 $ 2.07 $ 

$1.02 1.10 $ 2.01 $ $ 4.13 $ 0.25 0.00 $ 0.17 $ 

$ 0.87 0.72 $ 1.85 $ $ 3.45 $ 0.21 0.01 $ 0.14 $ 

$0.85 0.59 $ 0.43 $ $ 1.88 $ 0.11 0.01 $ 0.08 $ 

$ 1.94 0.74 $ 3.50 $ $ 6.19 $ - - $ - $ 

$ 6.14 17.24 $ 12.02 $ $ 35.40 $ 2.39 0.20 $ 2.45 $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

INCREMENTAL COST TO UPGRADE TO NE

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16

(Study Case# N010

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B010

Manufacturing Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-14, 34 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

15 Induction Air Charging Subsystem

01 Turbo Chargers (Assemblies)

A Turbo Charger Assembly 15 01 - N0101 - 01 1 Full 49.30 $ 26.79 $ 33.75 $ $ 109.84 $ 14.26 6.34 $ 15.29 $ 6.01 $ $ 41.90 $ 0

A1 Waste Gate Anti Surge Control Valve 15 01 - N0101 - 02 1 PIA

05 Heat Exchanger

A Cooler Assembly - Charged Air 15 05 - N0101 - 01 1 Full 6.91 $ 2.85 $ 6.44 $ $ 16.20 $ 0.97 0.08 $ 0.97 $ 0.32 $ $ 2.35 $ 0

70 Pipes, Hoses, Ducting

A Tube Assembly - Turbo Waste Gate Pneumatic Control 15 70 - N0101 - 03 1 Full 1.93 $ 1.12 $ 2.36 $ $ 5.41 $ 0.32 0.02 $ 0.22 $ 0.05 $ $ 0.61 $ 0

B Tube Ass'y w. Vehicle Tie Down Resonator, Air Cooler Inlet 15 70 - N0101 - 19 1 Full 4.98 $ 1.61 $ 2.16 $ $ 8.75 $ 0.53 0.03 $ 0.35 $ 0.09 $ $ 0.99 $ 0

BI Tube - Turbo Outlet to Vehicle Mount Coupler 15 70 - N0101 - 20 1 PIA

B2 Coupler - Turbo Outlet Tube to Cooler Intake Tube 15 70 - N0101 - 21 1 PIAB3 Tube - Coupler to Charge Air Cooler 15 70 - N0101 - 22 1 PIA

C Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet 15 70 N0101 30 1 Full 10.83 $ 2.65 $ 3.32 $ $ 16.81 $ 1.01 0.05 $ 0.67 $ 0.17 $ $ 1.90 $ 0

C1 Tube - Charge Air Cooler Outlet 15 70 - N0101 - 01 1 PIA

C2 Tube - Formed, Charge Air Cooler Tube Outlet 15 70 - N0101 - 31 1 PIAD Tube - Elbow, Upper to Charged Air Coupler By-Pass 15 70 - N0101 - 40 1 Full 2.26 $ 0.58 $ 1.08 $ $ 3.92 $ 0.24 0.01 $ 0.16 $ 0.04 $ $ 0.44 $ 0

E Tube - Coupler Y Branch to By-Pass 15 70 - N0101 - 41 1 (E,F,G, H Combined) Full 5.48 $ 2.48 $ 3.77 $ $ 11.73 $ 0.70 0.04 $ 0.47 $ 0.12 $ $ 1.33 $ 0F Tube - Elbow Coupler By-Pass to Throttle Body 15 70 - N0101 - 42 1 PIA

G Tube - Charged Air Bypass to Silencer 15 70 - N0101 - 43 1 PIAH Tube - Flex Elbow, Silencer to Environment 15 70 - N0101 - 44 1 PIA

75 Brackets

A Bracket - Support, Turbo Assembly 15 75 - N0101 - 01 1 Full 1.07 $ 0.15 $ 0.39 $ $ 1.61 $ 0.10 0.00 $ 0.06 $ - $ $ 0.17 $ 0

80 Boltings, Clamps, Misc Fastening

C Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 03 1 PIA Engine Assembly

D Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 04 1 PIA Engine AssemblyE Bolt - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 05 2 PIA Engine AssemblyF Nut - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 06 1 PIA Engine AssemblyH Clamp - Tube, Large, Turbo to Throttle Body 15 80 - N0101 - 08 9 PIA To HosesI Bolt - Tube, Charge Air Cooler to Vehicle 15 80 - N0101 - 09 2 PIA Engine AssemblyJ Screw - Sensor, Charge Air Temperature 15 80 - N0101 - 10 1 PIA Tube Charged AirL Clamp - Tubing Charged Air By-Pass 15 80 - N0101 - 12 3 PIA To HosesM Retainer - Vehicle, Charged Air By-Pass Elbow 15 80 - N0101 - 13 1 PIA Tube-Flex Elbow...

99 Miscellaneous

A Vacuum Reservoir - Turbo Waste Gate 15 99 - N0101 - 01 1 Full 1.08 $ 0.34 $ 0.63 $ $ 2.05 $ 0.22 0.01 $ 0.18 $ 0.05 $ $ 0.48 $ 0

B Value - Thrust Control, Turbo Waste Gate Pneumatic Control 15 99 - N0101 - 02 1 Full 5.19 $ - $ - $ $ 5.19 $ 0.34 0.03 $ 0.31 $ 0.13 $ $ 0.80 $ 0

C Sensor - Intake Temperature, Outlet Charged Air Cooler 15 99 - N0101 - 03 1 PIA Tube Charged Air

D Baffle - Charge Air By-Pass 15 99 - N0101 - 04 1 PIA Tube-Flex Elbow...

100 Vehicle/Engine Assembly

A Engine and Vehicle Asssembly of Air Induction Components Full 1.14 $ 9.81 $ 14.75 $ $ 25.70 $ - - $ - $ - $ $ - $ 

$90.16 48.38 $ 68.66 $ $ 207.21 $ 18.68 6.61 $ 18.69 $ 6.98 $ $ 50.97 $ 0

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing 

differentials are accounted for in the quote sheet of the competing technology.

Markup Total Markup 

Cost 

(Component/ 

Assembly)

Tota

Packag

Cos

(Compo

/ Assem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

Sub-Subsystem

Assembly

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. 

(Study Case# N0101)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-15, 35 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

15 Induction Air Charging Subsystem

01 Turbo Chargers (Assemblies)

A Turbo Charger Assembly 15 01 - N0101 - 01 1 Full

A1 Waste Gate Anti Surge Control Valve 15 01 - N0101 - 02 1 PIA

05 Heat Exchanger

A Cooler Assembly - Charged Air 15 05 - N0101 - 01 1 Full

70 Pipes, Hoses, Ducting

A Tube Assembly - Turbo Waste Gate Pneumatic Control 15 70 - N0101 - 03 1 Full

B Tube Ass'y w. Vehicle Tie Down Resonator, Air Cooler Inlet 15 70 - N0101 - 19 1 Full

BI Tube - Turbo Outlet to Vehicle Mount Coupler 15 70 - N0101 - 20 1 PIAB2 Coupler - Turbo Outlet Tube to Cooler Intake Tube 15 70 - N0101 - 21 1 PIAB3 Tube - Coupler to Charge Air Cooler 15 70 - N0101 - 22 1 PIA

C Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet 15 70 N0101 30 1 Full

C1 Tube - Charge Air Cooler Outlet 15 70 - N0101 - 01 1 PIA

C2 Tube - Formed, Charge Air Cooler Tube Outlet 15 70 - N0101 - 31 1 PIAD Tube - Elbow, Upper to Charged Air Coupler By-Pass 15 70 - N0101 - 40 1 FullE Tube - Coupler Y Branch to By-Pass 15 70 - N0101 - 41 1 (E,F,G, H Combined) FullF Tube - Elbow Coupler By-Pass to Throttle Body 15 70 - N0101 - 42 1 PIAG Tube - Charged Air Bypass to Silencer 15 70 - N0101 - 43 1 PIAH Tube - Flex Elbow, Silencer to Environment 15 70 - N0101 - 44 1 PIA

75 Brackets

A Bracket - Support, Turbo Assembly 15 75 - N0101 - 01 1 Full

80 Boltings, Clamps, Misc Fastening

C Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 03 1 PIA Engine Assembly

D Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 04 1 PIA Engine AssemblyE Bolt - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 05 2 PIA Engine AssemblyF Nut - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 06 1 PIA Engine AssemblyH Clamp - Tube, Large, Turbo to Throttle Body 15 80 - N0101 - 08 9 PIA To HosesI Bolt - Tube, Charge Air Cooler to Vehicle 15 80 - N0101 - 09 2 PIA Engine AssemblyJ Screw - Sensor, Charge Air Temperature 15 80 - N0101 - 10 1 PIA Tube Charged AirL Clamp - Tubing Charged Air By-Pass 15 80 - N0101 - 12 3 PIA To HosesM Retainer - Vehicle, Charged Air By-Pass Elbow 15 80 - N0101 - 13 1 PIA Tube-Flex Elbow...

99 Miscellaneous

A Vacuum Reservoir - Turbo Waste Gate 15 99 - N0101 - 01 1 Full

B Value - Thrust Control, Turbo Waste Gate Pneumatic Control 15 99 - N0101 - 02 1 Full

C Sensor - Intake Temperature, Outlet Charged Air Cooler 15 99 - N0101 - 03 1 PIA Tube Charged Air

D Baffle - Charge Air By-Pass 15 99 - N0101 - 04 1 PIA Tube-Flex Elbow...

100 Vehicle/Engine Assembly

A Engine and Vehicle Asssembly of Air Induction Components Full

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing 

differentials are accounted for in the quote sheet of the competing technology.

Item

Subsystem

Sub-Subsystem

Assembly

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

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

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

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

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

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

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

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

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

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

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Total Markup 

Cost 

(Component/ 

Assembly)

Tota

Packag

Cost 

(Compo

/ Assem

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFI w. 

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-15, 36 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

15 Induction Air Charging Subsystem

01 Turbo Chargers (Assemblies)

A Turbo Charger Assembly 15 01 - N0101 - 01 1 Full

A1 Waste Gate Anti Surge Control Valve 15 01 - N0101 - 02 1 PIA

05 Heat Exchanger

A Cooler Assembly - Charged Air 15 05 - N0101 - 01 1 Full

70 Pipes, Hoses, Ducting

A Tube Assembly - Turbo Waste Gate Pneumatic Control 15 70 - N0101 - 03 1 Full

B Tube Ass'y w. Vehicle Tie Down Resonator, Air Cooler Inlet 15 70 - N0101 - 19 1 Full

BI Tube - Turbo Outlet to Vehicle Mount Coupler 15 70 - N0101 - 20 1 PIAB2 Coupler - Turbo Outlet Tube to Cooler Intake Tube 15 70 - N0101 - 21 1 PIAB3 Tube - Coupler to Charge Air Cooler 15 70 - N0101 - 22 1 PIA

C Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet 15 70 N0101 30 1 Full

C1 Tube - Charge Air Cooler Outlet 15 70 - N0101 - 01 1 PIA

C2 Tube - Formed, Charge Air Cooler Tube Outlet 15 70 - N0101 - 31 1 PIAD Tube - Elbow, Upper to Charged Air Coupler By-Pass 15 70 - N0101 - 40 1 FullE Tube - Coupler Y Branch to By-Pass 15 70 - N0101 - 41 1 (E,F,G, H Combined) FullF Tube - Elbow Coupler By-Pass to Throttle Body 15 70 - N0101 - 42 1 PIAG Tube - Charged Air Bypass to Silencer 15 70 - N0101 - 43 1 PIAH Tube - Flex Elbow, Silencer to Environment 15 70 - N0101 - 44 1 PIA

75 Brackets

A Bracket - Support, Turbo Assembly 15 75 - N0101 - 01 1 Full

80 Boltings, Clamps, Misc Fastening

C Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 03 1 PIA Engine Assembly

D Bolt - Bracket Support, Turbo Assembly 15 80 - N0101 - 04 1 PIA Engine AssemblyE Bolt - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 05 2 PIA Engine AssemblyF Nut - Pressure Reservoir, Turbo Waste Gate 15 80 - N0101 - 06 1 PIA Engine AssemblyH Clamp - Tube, Large, Turbo to Throttle Body 15 80 - N0101 - 08 9 PIA To HosesI Bolt - Tube, Charge Air Cooler to Vehicle 15 80 - N0101 - 09 2 PIA Engine AssemblyJ Screw - Sensor, Charge Air Temperature 15 80 - N0101 - 10 1 PIA Tube Charged AirL Clamp - Tubing Charged Air By-Pass 15 80 - N0101 - 12 3 PIA To HosesM Retainer - Vehicle, Charged Air By-Pass Elbow 15 80 - N0101 - 13 1 PIA Tube-Flex Elbow...

99 Miscellaneous

A Vacuum Reservoir - Turbo Waste Gate 15 99 - N0101 - 01 1 Full

B Value - Thrust Control, Turbo Waste Gate Pneumatic Control 15 99 - N0101 - 02 1 Full

C Sensor - Intake Temperature, Outlet Charged Air Cooler 15 99 - N0101 - 03 1 PIA Tube Charged Air

D Baffle - Charge Air By-Pass 15 99 - N0101 - 04 1 PIA Tube-Flex Elbow...

100 Vehicle/Engine Assembly

A Engine and Vehicle Asssembly of Air Induction Components Full

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing 

differentials are accounted for in the quote sheet of the competing technology.

Item

Subsystem

Sub-Subsystem

Assembly

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

$ 26.79 49.30 $ 33.75 $ $ 109.84 $ 14.26 6.34 $ 15.29 $ 6.01 $ $ 41.9

$ 2.85 6.91 $ 6.44 $ $ 16.20 $ 0.97 0.08 $ 0.97 $ 0.32 $ $ 2.3$ 1.12 1.93 $ 2.36 $ $ 5.41 $ 0.32 0.02 $ 0.22 $ 0.05 $ $ 0.6$ 1.61 4.98 $ 2.16 $ $ 8.75 $ 0.53 0.03 $ 0.35 $ 0.09 $ $ 0.9

$ 2.65 10.83 $ 3.32 $ $ 16.81 $ 1.01 0.05 $ 0.67 $ 0.17 $ $ 1.9

$ 0.58 2.26 $ 1.08 $ $ 3.92 $ 0.24 0.01 $ 0.16 $ 0.04 $ $ 0.4$ 2.48 5.48 $ 3.77 $ $ 11.73 $ 0.70 0.04 $ 0.47 $ 0.12 $ $ 1.3$ 0.15 1.07 $ 0.39 $ $ 1.61 $ 0.10 0.00 $ 0.06 $ - $ $ 0.1$ 0.34 1.08 $ 0.63 $ $ 2.05 $ 0.22 0.01 $ 0.18 $ 0.05 $ $ 0.4$ - 5.19 $ - $ $ 5.19 $ 0.34 0.03 $ 0.31 $ 0.13 $ $ 0.8$ 9.81 1.14 $ 14.75 $ $ 25.70 $ - - $ - $ - $ $ - 

$ 48.38 90.16 $ 68.66 $ $ 207.21 $ 18.68 6.61 $ 18.69 $ 6.98 $ $ 50.9

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY 

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turb

(Study Case# N0101)

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w

(Study Case# B0101)

Markup Total Marku

Cost 

(Componen

Assembly)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-15, 37 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

R&D

17 Breather Subsystem

02 Oil/Air Separator

A PCV ASSEMBLY - (Built into Cylinder Head Cover) 17 02 - N0101 - 00 1 1 Diff $ 0.37 1.35 $ 1.49 $ $ 3.21 $ 0.42 0.03 $ 0.39 $ 0.1

$ 

A1 Valve - Non Return Intake Hose Side 17 02 - N0101 - 01 1A2 Separator - Cyclone 17 02 - N0101 - 10 1A3 Valve - Pressure Control 17 02 - N0101 - 20 1A4 Valve - Oil Drain 17 02 - N0101 - 30 1A5 Valve - Non Return Intake Manifold Side 17 02 - N0101 - 40 1

100 Engine Assembly

A Engine Assembly Additions/Modifications for Breather Subsystem NA $ - - $ - $ $ - $ - - $ - $ - $ 

$1.35 0.37 $ 1.49 $ $ 3.21 $ 0.42 0.03 $ 0.39 $ 0.1

$ 

NOTES:

1.

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

Markup

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V D

(Study Case# N0101)

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-17, 38 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

17 Breather Subsystem

02 Oil/Air Separator

A PCV ASSEMBLY - (Built into Cylinder Head Cover) 17 02 - N0101 - 00 1 1 Diff

A1 Valve - Non Return Intake Hose Side 17 02 - N0101 - 01 1A2 Separator - Cyclone 17 02 - N0101 - 10 1A3 Valve - Pressure Control 17 02 - N0101 - 20 1A4 Valve - Oil Drain 17 02 - N0101 - 30 1A5 Valve - Non Return Intake Manifold Side 17 02 - N0101 - 40 1

100 Engine Assembly

A Engine Assembly Additions/Modifications for Breather Subsystem NA

NOTES:

1.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

R&D

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

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V 

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-17, 39 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

17 Breather Subsystem

02 Oil/Air Separator

A PCV ASSEMBLY - (Built into Cylinder Head Cover) 17 02 - N0101 - 00 1 1 Diff

A1 Valve - Non Return Intake Hose Side 17 02 - N0101 - 01 1A2 Separator - Cyclone 17 02 - N0101 - 10 1A3 Valve - Pressure Control 17 02 - N0101 - 20 1A4 Valve - Oil Drain 17 02 - N0101 - 30 1A5 Valve - Non Return Intake Manifold Side 17 02 - N0101 - 40 1

100 Engine Assembly

A Engine Assembly Additions/Modifications for Breather Subsystem NA

NOTES:

1.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Subassembly

Component Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

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

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$1.35 0.37 $ 1.49 $ $ 3.21 $ 0.42 0.03 $ 0.3

$ 

$0.00 - $ - $ $ - $ - - $ - $ 

$ 0.37 1.35 $ 1.49 $ $ 3.21 $ 0.42 0.03 $ 0.3

$ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NE

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16

(Study Case# N01

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B01

Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-17, 40 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Material Labor Burden End Item Scrap SG&A Profit ED

R&

60 Engine Management, Engine Electronic and Electrical Subsystems

02 Engine Management Systems, Engine Electronic Systems

A Power Train Control Module (PCM) Assembly - Hardware 60 02 - N0101 - 01 1 Diff. 40.00 $ - $ - $ $ 40.00 $ - - $ - $ 

$ 

B Power Train Control Module (PCM) Assembly - Software 60 02 - N0101 - 50 1 Included in Indirect Cost (IC)Multiplier NA $0.00 $0.00 $0.00 $ - $ - - $ - $ 

$ 

03

Diff. $12.13 $0.00 $0.00 $ 12.13 $ - - $ - $ 

$ 

A Ignition Coil Assembly - Single Spark 60 03 - N0101 - 01 4 PIA to Engine Assembly

C Wire Harness Assembly #1 - Engine, Main 60 03 - N0101 - 30 1 PIA to Engine Assembly

100 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

A Assembly Modification & Addition to Engine Management & Electrical Subsystems Added Electrical Connections Diff. $ 1.60 - $ 2.88 $ $ 4.48 $ - - $ - $ 

$ 

$52.13 1.60 $ 2.88 $ $ 56.61 $ - - $ - $ 

$ 

NOTES:

1.

Subassembly 

Component Name/Description Part Number Total Manufacturing Cost (Component/ Assembly) Markup 

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V D

(Study Case# N0101)

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

Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

Manufacturing 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-60, 41 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

60 Engine Management, Engine Electronic and Electrical Subsystems

02 Engine Management Systems, Engine Electronic Systems

A Power Train Control Module (PCM) Assembly - Hardware 60 02 - N0101 - 01 1 Diff.

B Power Train Control Module (PCM) Assembly - Software 60 02 - N0101 - 50 1 Included in Indirect Cost (IC)Multiplier NA

03

Diff.

A Ignition Coil Assembly - Single Spark 60 03 - N0101 - 01 4 PIA to Engine Assembly

C Wire Harness Assembly #1 - Engine, Main 60 03 - N0101 - 30 1 PIA to Engine Assembly

100 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

A Assembly Modification & Addition to Engine Management & Electrical Subsystems Added Electrical Connections Diff.

NOTES:

1.

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

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

Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

R&

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

$ 

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

$ 

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

$ 

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

$ 

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

$ 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V 

(Study Case# B0101)

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-60, 42 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

60 Engine Management, Engine Electronic and Electrical Subsystems

02 Engine Management Systems, Engine Electronic Systems

A Power Train Control Module (PCM) Assembly - Hardware 60 02 - N0101 - 01 1 Diff.

B Power Train Control Module (PCM) Assembly - Software 60 02 - N0101 - 50 1 Included in Indirect Cost (IC)Multiplier NA

03

Diff.

A Ignition Coil Assembly - Single Spark 60 03 - N0101 - 01 4 PIA to Engine Assembly

C Wire Harness Assembly #1 - Engine, Main 60 03 - N0101 - 30 1 PIA to Engine Assembly

100 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

A Assembly Modification & Addition to Engine Management & Electrical Subsystems Added Electrical Connections Diff.

NOTES:

1.

Subassembly

Component Name/Description Part Number

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

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

Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Prof

$40.00 - $ - $ $ 40.00 $ - - $ 

$ 

$0.00 - $ - $ $ - $ - - $ 

$ 

$12.13 - $ - $ $ 12.13 $ - - $ 

$ 

$0.00 1.60 $ 2.88 $ $ 4.48 $ - - $ 

$ 

$ 1.60 52.13 $ 2.88 $ $ 56.61 $ - - $ 

$ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO N

NEW TECHNOLOGY PACKAGE: 1.6L I4, 1

(Study Case# N0

BASE TECHNOLOGY PACKAGE: 2.4L 

(Study Case# B0

Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-60, 43 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

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

R&D

70 Accessories Subsystem (Starter Engines, Generators, Power Steering Pumps, etc)

04 Vacuum Pumps

A Vacuum Pump Assembly 70 04 - N0101 - 01 1 1 Full $ 1.81 3.31 $ 6.56 $ $ 11.69 $ 1.41 0.09 $ 1.15 $ 0.3

$ 

80 Boltings

A Bolt - Vacuum Pump 70 80 - N0101 - 01 2 PIA Engine Assembly 1 Full

100 Engine Assembly

A Engine Assembly Additions/Modifications for Accessory Subsystem 1 Full $ 0.74 0.13 $ 1.34 $ $ 2.20 $ - - $ - $ - $ 

$3.44 2.55 $ 7.90 $ $ 13.89 $ 1.41 0.09 $ 1.15 $ 0.3

$ 

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V D

(Study Case# N0101) GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Markup

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-70, 44 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

70 Accessories Subsystem (Starter Engines, Generators, Power Steering Pumps, etc)

04 Vacuum Pumps

A Vacuum Pump Assembly 70 04 - N0101 - 01 1 1 Full

80 Boltings

A Bolt - Vacuum Pump 70 80 - N0101 - 01 2 PIA Engine Assembly 1 Full

100 Engine Assembly

A Engine Assembly Additions/Modifications for Accessory Subsystem 1 Full

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

R&D

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

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

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

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V 

(Study Case# B0101)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-70, 45 of 46 
SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

70 Accessories Subsystem (Starter Engines, Generators, Power Steering Pumps, etc)

04 Vacuum Pumps

A Vacuum Pump Assembly 70 04 - N0101 - 01 1 1 Full

80 Boltings

A Bolt - Vacuum Pump 70 80 - N0101 - 01 2 PIA Engine Assembly 1 Full

100 Engine Assembly

A Engine Assembly Additions/Modifications for Accessory Subsystem 1 Full

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row 

 indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.

GENERAL PART INFORMATION

QTY/

P.T Notes

LevelFull Mod. Diff.

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component Name/Description Part Number

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

Material Labor Burden End Item Scrap SG&A Profit 

$3.31 1.81 $ 6.56 $ $ 11.69 $ 1.41 0.09 $ 1.

$ 

$ 0.74 0.13 $ 1.34 $ $ 2.20 $ - - $ - $ 

$ 2.55 3.44 $ 7.90 $ $ 13.89 $ 1.41 0.09 $ 1.1

$ 

Markup

BASE TECHNOLOGY PACKAGE: 2.4L I4

(Study Case# B01

INCREMENTAL COST TO UPGRADE TO NE

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16

(Study Case# N01

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix H.1-70, 46 of 46 
APPENDIX H.2 SYSTEM COST MODEL ANALYSIS TEMPLATE (CMA

Case Study #0101

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

02 No Modifications or Additions Required 1 NA

03 Crank Drive Subsystem Last Updated 5/20/09 1 Mod. $ (4.09) $ 4.15 0.39 $ $ 0.46 $ 0.28 $ (0.51) (0.37) $ $ 0.14 $ (0.46) $ 

04 Counter Balance Subsystem Last Updated 5/20/09 1 TBD $ - - $ - $ $ - $ - - $ - $ - $ $ - $ 05 Cylinder Block Subsystem Last Updated 5/20/09 1 Mod. $ (7.59) $ 5.78 1.36 $ $ (0.46) $ (0.53) $ 0.56 0.83 $ - $ $ 0.86 $ 06 Cylinder Head Subsystem Last Updated 5/20/09 1 Mod. $ 0.81 5.57 $ 6.94 $ $ 13.32 $ 0.65 1.80 $ 0.71 $ 0.04 $ $ 3.20 $ 07 Valve Train Subsystem Last Updated 5/20/09 1 Mod $8.40 - $ - $ $ 8.40 $ 0.59 0.05 $ 0.68 $ 0.34 $ $ 1.65 $ 08 Timing Drive Subsystem Last Updated 5/20/09 1 Mod $1.60 - $ - $ $ 1.60 $ - - $ - $ - $ $ - $ 09 Accessory Drive Subsystem No Modifications or Additions Required 1 NA

10 Intake Subsystem Last Updated 5/20/09 1 NA ($10.66) (0.01) $ (0.10) $ $ (10.78) $ (0.70) (0.05) $ (0.65) $ (0.27) $ $ (1.67) $ 

11 Fuel Induction Subsystem Last Update 5/20/09 1 Add & Mod $37.25 17.41 $ 62.87 $ $ 117.53 $ 12.30 1.23 $ 12.25 $ 4.67 $ $ 30.44 $ 12 Exhaust Subsystem Last Updated 5/20/09 1 Mod $27.24 0.11 $ 3.09 $ $ 30.44 $ 1.97 2.97 $ 1.79 $ 0.71 $ $ 7.44 $ 13 Last Updated 5/20/09 1 Add & Mod $12.63 5.30 $ 11.74 $ $ 29.67 $ 2.13 0.14 $ 1.78 $ 0.51 $ $ 4.55 $ 14 Cooling Subsystem Last Updated 5/20/09 1 Add $17.24 6.14 $ 12.02 $ $ 35.40 $ 2.39 0.20 $ 2.45 $ 1.03 $ $ 6.06 $ 15 Induction Air Charging Subsystem Last Updated 5/20/09 1 Add $90.16 48.38 $ 68.66 $ $ 207.21 $ 18.68 6.61 $ 18.69 $ 6.98 $ $ 50.97 $ 16

Subsystem does not exist on either Base or New Technology Package.

1 NA

17 Breather Subsystem Last Updated 5/20/09 1 Mod $1.35 0.37 $ 1.49 $ $ 3.21 $ 0.42 0.03 $ 0.39 $ 0.12 $ $ 0.96 $ 60 Last Updated 5/20/09 1 Mod $52.13 1.60 $ 2.88 $ $ 56.61 $ - - $ - $ - $ $ - $ 70 Last Updated 4/2/09 1 Add. $3.44 2.55 $ 7.90 $ $ 13.89 $ 1.41 0.09 $ 1.15 $ 0.32 $ $ 2.96 $ 

$ 84.41 234.68 $ 187.40 $ $ 506.50 $ 40.28 12.81 $ 39.29 $ 14.59 $ $ 106.97 $ 

NOTES:

1.

Markup Total Markup 

Cost 

(Component/ 

Assembly)

T

Pac

(Com

/ As

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

GENERAL PART INFORMATION

Notes

Level Addition or Modification

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

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w

(Study Case# N0101)

Engine Management Systems, Engine Electronic Systems, Electrical SubsystemsAccessory Subsystems (Starter Engines, Generators, Power Steering Pumps, etc)

Subsystem Description

Engine Frames, Mountings & Brackets SubsystemExhaust Gas Re-Circulation SubsystemLubrication Subsystems (Oil Pans/Sumps)

Manufacturing 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

File:SYSCMAT_CS0101-H.2 -120809.xlsEPA Contract:EP-C-07-069 WA1-3 H.2, Page 1 of 3 
APPENDIX H.2 SYSTEM COST MODEL ANALYSIS TEMPLATE (CMA

Case Study #0101

02 No Modifications or Additions Required 1 NA

03 Crank Drive Subsystem Last Updated 5/20/09 1 Mod.04 Counter Balance Subsystem Last Updated 5/20/09 1 TBD

05 Cylinder Block Subsystem Last Updated 5/20/09 1 Mod.

06 Cylinder Head Subsystem Last Updated 5/20/09 1 Mod.07 Valve Train Subsystem Last Updated 5/20/09 1 Mod

08 Timing Drive Subsystem Last Updated 5/20/09 1 Mod09 Accessory Drive Subsystem No Modifications or Additions Required 1 NA

10 Intake Subsystem Last Updated 5/20/09 1 NA11 Fuel Induction Subsystem Last Update 5/20/09 1 Add & Mod12 Exhaust Subsystem Last Updated 5/20/09 1 Mod13 Last Updated 5/20/09 1 Add & Mod14 Cooling Subsystem Last Updated 5/20/09 1 Add15 Induction Air Charging Subsystem Last Updated 5/20/09 1 Add

16

Subsystem does not exist on either Base or New Technology Package.

1 NA

17 Breather Subsystem Last Updated 5/20/09 1 Mod

60 Last Updated 5/20/09 1 Mod70 Last Updated 4/2/09 1 Add.

NOTES:

1.

Item

Subsystem

GENERAL PART INFORMATION

Notes

Level Addition or Modification

 = A highlighted Sub-subsystem, Assembly or Component row  indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.Engine Management Systems, Engine Electronic Systems, Electrical SubsystemsAccessory Subsystems (Starter Engines, Generators, Power Steering Pumps, etc)

Subsystem Description

Engine Frames, Mountings & Brackets SubsystemExhaust Gas Re-Circulation SubsystemLubrication Subsystems (Oil Pans/Sumps)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

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

$ 6.22 10.37 $ 11.36 $ $ 27.94 $ 3.22 0.82 $ 2.98 $ 0.92 $ $ 7.95 $ 

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

$ 5.61 5.49 $ 21.81 $ $ 32.91 $ 3.10 0.27 $ 3.19 $ 1.31 $ $ 7.87 $ 

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

$ 11.83 15.86 $ 33.17 $ $ 60.86 $ 6.33 1.10 $ 6.16 $ 2.23 $ $ 15.82 $ 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Total Markup 

Cost 

(Component/ 

Assembly)

To

Packa

Co

(Comp

/ Asse

Manufacturing 

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFI w

(Study Case# B0101)

File:SYSCMAT_CS0101-H.2 -120809.xlsEPA Contract:EP-C-07-069 WA1-3 H.2, Page 2 of 3 
APPENDIX H.2 SYSTEM COST MODEL ANALYSIS TEMPLATE (CMA

Case Study #0101

02 No Modifications or Additions Required 1 NA

03 Crank Drive Subsystem Last Updated 5/20/09 1 Mod.04 Counter Balance Subsystem Last Updated 5/20/09 1 TBD

05 Cylinder Block Subsystem Last Updated 5/20/09 1 Mod.

06 Cylinder Head Subsystem Last Updated 5/20/09 1 Mod.07 Valve Train Subsystem Last Updated 5/20/09 1 Mod

08 Timing Drive Subsystem Last Updated 5/20/09 1 Mod09 Accessory Drive Subsystem No Modifications or Additions Required 1 NA

10 Intake Subsystem Last Updated 5/20/09 1 NA11 Fuel Induction Subsystem Last Update 5/20/09 1 Add & Mod12 Exhaust Subsystem Last Updated 5/20/09 1 Mod13 Last Updated 5/20/09 1 Add & Mod14 Cooling Subsystem Last Updated 5/20/09 1 Add15 Induction Air Charging Subsystem Last Updated 5/20/09 1 Add

16

Subsystem does not exist on either Base or New Technology Package.

1 NA

17 Breather Subsystem Last Updated 5/20/09 1 Mod

60 Last Updated 5/20/09 1 Mod70 Last Updated 4/2/09 1 Add.

NOTES:

1.

Item

Subsystem

GENERAL PART INFORMATION

Notes

Level Addition or Modification

 = A highlighted Sub-subsystem, Assembly or Component row  indicates design and/or manufacturing differentials are accounted  for in the quote sheet of the competing technology.Engine Management Systems, Engine Electronic Systems, Electrical SubsystemsAccessory Subsystems (Starter Engines, Generators, Power Steering Pumps, etc)

Subsystem Description

Engine Frames, Mountings & Brackets SubsystemExhaust Gas Re-Circulation SubsystemLubrication Subsystems (Oil Pans/Sumps)

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine

Vehicle Class: Compact/Economy 2-4 Passenger

Study Case#: N0101 & B0101 (N=New, B=Base, ) 01=Technology Package, 

 01=Vehicle Class

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

$ (4.09) $ 4.15 0.39 $ $ 0.46 $ 0.28 $ (0.51) (0.37) $ $ 0.14 $ (0.46) $ 

$ (6.22) (10.37) $ (11.36) $ $ (27.94) $ (3.22) (0.82) $ (2.98) $ (0.92) $ $ (7.95) $ 

$ (7.59) $ 5.78 1.36 $ $ (0.46) $ (0.53) $ 0.56 0.83 $ - $ $ 0.86 $ 

$ 0.81 5.57 $ 6.94 $ $ 13.32 $ 0.65 1.80 $ 0.71 $ 0.04 $ $ 3.20 $ $ - 8.40 $ - $ $ 8.40 $ 0.59 0.05 $ 0.68 $ 0.34 $ $ 1.65 $ $ - 1.60 $ - $ $ 1.60 $ - - $ - $ - $ $ - $ 

$ (0.01) (10.66) $ (0.10) $ $ (10.78) $ (0.70) (0.05) $ (0.65) $ (0.27) $ $ (1.67) $ 

$ 11.80 31.76 $ 41.05 $ $ 84.62 $ 9.20 0.95 $ 9.06 $ 3.36 $ $ 22.58 $ $ 0.11 27.24 $ 3.09 $ $ 30.44 $ 1.97 2.97 $ 1.79 $ 0.71 $ $ 7.44 $ $ 5.30 12.63 $ 11.74 $ $ 29.67 $ 2.13 0.14 $ 1.78 $ 0.51 $ $ 4.55 $ $ 6.14 17.24 $ 12.02 $ $ 35.40 $ 2.39 0.20 $ 2.45 $ 1.03 $ $ 6.06 $ $ 48.38 90.16 $ 68.66 $ $ 207.21 $ 18.68 6.61 $ 18.69 $ 6.98 $ $ 50.97 $ $ 0.37 1.35 $ 1.49 $ $ 3.21 $ 0.42 0.03 $ 0.39 $ 0.12 $ $ 0.96 $ $ 1.60 52.13 $ 2.88 $ $ 56.61 $ - - $ - $ - $ $ - $ $ 2.55 3.44 $ 7.90 $ $ 13.89 $ 1.41 0.09 $ 1.15 $ 0.32 $ $ 2.96 $ 

$ 72.58 218.82 $ 154.24 $ $ 445.64 $ 33.96 11.72 $ 33.12 $ 12.36 $ $ 91.16 $ 

(C

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Total Markup 

Cost 

(Component/ 

Assembly)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PA

NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo 

(Study Case# N0101)

BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. d

(Study Case# B0101)

File:SYSCMAT_CS0101-H.2 -120809.xlsEPA Contract:EP-C-07-069 WA1-3 H.2, Page 3 of 3