# 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 Da tabase ..................................................................................................... 7-3

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

7.2.2 Material Selec tion 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

# ii 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 C ontributors 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 Contributor s 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 Summa ry 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 Assumpti on 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 Anal ysis Templates – Case Study #0101

H.2 System Cost Model Analys is Template – Case Study #0101

# iv 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 Mappi ng 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 Pr imary 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 Libr ary – Design Profit® Database............................4-15

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

Figure 4-9: Example Illustrating the Various Le vels 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 La bor Rates between 2008 and 2015, Assuming a

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

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

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

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

Figure 7-4: Historical 304 Stai nless Steel Prices.................................................................7-7

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

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

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

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

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

Figure 7-8: Manufacturing Overhead Database Ex cerpt Showing Standard Overhead Rates

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

Figure 7-9: Mark-up Database Excerpt Highlighti ng 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

# v Figure 9-1: Excerpt Illustrating Automated Link between OEM/T1 Classification Input in

MAQS Worksheet and the Corresponding Ma rk-up Percentages Uploaded from

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

Figure 9-2: Example of Packaging Cost Calcula tion 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 S ubsystem - 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 Templa te 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 Co st Impact - Downsizing from a 2.4L I4, 16

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

.............................................................................................................................. E S-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 Classifi cation 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 Agen cy (EPA) contracted with FEV, Inc. to

determine incremental direct manufacturing cost s 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. Analys ts with expertise in automotive design,

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

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

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

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

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

identify sources of information, describe assu mptions used in the ca se study, and provide

analysis tools (such as forecasting to future years).

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

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

on a downsized I4 engine, compared to an equivalent conventiona l 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, a ll 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 s ubsystem included the

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

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

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

fuel induction subsystem incl uded the addition of a high pr essure 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 confi guration costs which

included four (4) low pressure fuel injector s ($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 (subsyste m 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, Mounti ngs & 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 ve hicle technology cost

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

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

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

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

downsized I4 engine, compared to an equi valent conventional I4 engine (Case Study

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

Appendix; however, the very la rge size of some of the anal ysis 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/). Co sting results and de tails for additional

technologies and vehicle classes will be provided in s ubsequent reports.

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

costs for a set of advanced light-duty vehicl e 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). Su ch reductions generally correspond to fuel

economy improvements. Each technology sele cted is evaluated against a baseline

vehicle technology configur ation, representative of the curre nt state of design, and having

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

vehicle fleet, application of the new technol ogies 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 vehicl e class. The vehicle size classes are:

• Small car: a subcompact or compact car t ypically 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 e ngine, 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 unde r 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 comp ression 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 Cla ss Summary Matrix (P-VCSM) a technology

is selected for cost analysis.

The P-VCSM identifies the technologies being ev aluated, the applicable vehicle

classes for each technology, and key parame ters for vehicles or vehicle systems

that have been selected to repr esent 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 th at some closely associated technologies

are bundled; for example: gasoline dir ect injection and turbocharging.

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

detailed incremental cost calculations. The t eardown vehicles are chosen in collaboration

with EPA to represent the base and ne w 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 affect ed by the addition of a new technology, such

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

performance details of the selected new and base technology configur ations are recorded

in the Powertrain Package Proforma.

The Powertrain Package Proforma is a summary worksh eet comparing the key

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

the corresponding base configur ation. The Powertrain Package Proforma for case

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

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

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

CBOM’s are informed by the team’s understandi ng of the new and ba se 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 ve hicle that are not

used on the base vehicle.

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

the base and new technology configurations, as a resu lt of adoption of the new

technology. Also the CBOM is the documen t used to capture alternative design

# 1-5 and manufacturing innovations, which can be binned to either material cost

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

technology configurati ons 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), valid ation quote required, etc. In the context of this

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

assembly, not a price provided by a s upplier. 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 conducte d 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 hi gh 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 assemb ly or component. A single component

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

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

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

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

logical manner is very critical.

Fundamental to process mapping is iden tifying 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 a ll the data generated from the high level

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

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

and driveline subsystems, vehicle integra tion, production devel opment, manufacturing

engineering (supplier and OEM), cost es timating and product be nchmarking. Where

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

technology under analysis.

The CFT captures the assessm ents in the CBOMs, identifying the component and

assembly differences between the new a nd base technology conf igurations. All

# 1-6 components requiring cost analysis are identifie d, as well as any base assumptions where

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

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

CBOM’s. Components and assemblies are di sassembled, and processes and operations

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

quote worksheets. Several databases, contai ning critical costing in formation, 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 activ e links to all key costing parameters.

The MAQS worksheet is basically a standard original equipment manufacturer

(OEM) quote sheet modified with some extr a 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 wo rksheet are the manufacturing assumption

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

key output variables from the process ma ps 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 secti on 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 unexpect ed cost results are subjected to a marketplace crosscheck such as comparison w ith supplier price quotes, or wider consultation with

company and industry re sources beyond the CFT.

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

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

contained within the engine system, incl ude the following: crankdrive subsystem,

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

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

associated with a subsystem. All part s in a subsystem that are identified for

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

and new technology configura tions are included in the same CMAT to facilitate

differential cost analysis.

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

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

#0101, the engine system was the only ve hicle system requiring analysis.

The System CMAT , similar in function to the s ubsystem CMAT, is the document

used to display and roll-up all the subsyste m costs associated w ithin a system, as

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

provides the bottom line incremental un it cost, between the base and new

technology configurations under evaluation. All Subs ystem CMAT totals are

linked directly to the System CMAT.

1.3 Manufacturing Assumptions



# When conducting the cost analysis for the various technology conf igurations, a number

of assumptions are made in orde r 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 appl y to all technology c onfigurations under

analysis. Listed below are the fundamental assumptions:

1) All OEM and supplier manufacturing loca tions 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 manufacturi ng equipment and facilities capable of

handling required manufacturing processe s and capacities, unless otherwise

stated.

# 1-8 3) All manufacturing processes and operati ons are based on standard/mainstream

industrial practices.

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

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

production volumes, significant mark etplace competition, established

manufacturing processes) unless otherwise specified.

5) All OEM mark-up will be applied using i ndirect cost (IC) mu ltipliers. These are

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

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

manufacturing costs.

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

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

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

Automotive Yearbook 2008, in which a nnual engine volumes for 2007 model

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

moderate to high volume c onsumption applications.

The specific case study assumptions ar e those unique to a given technology

configuration. These include volume assump tions, 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 Ma trix (P-VCSM) summarizes the technology

configurations and vehicle classes to be eval uated. 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 thes e configurations, along

with other pertinent vehicle/system details, ar e 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 tim e consuming. Fortunately, reliable results can be

obtained through judicious scaling of the teardown-derive d 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 comple x 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 c ount (number of pistons , for example) or

other parameters. The P-VCSM identifies wh ich 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 i ndividual 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 tec hnology configurations

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

versus base technology differe nces, documents the study assu mptions, 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 imp act on components and assemblies directly

associated with new technologies, the “ri pple effect” on neighbori ng systems must be

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

vehicle costs for the new technologies.

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

differences between the base and new technol ogy configurations bei ng studied as well as

the surrounding systems, which may be a ffected by the technol ogy differences. A

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

subsystem and component/assembly costs direc tly or indirectly a ssociated with the

technology change. Thus, rega rdless 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 na turally-aspirated I-4

engine is replaced by a downsized, turbocharg ed I-4 engine, the te am concluded that no

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

overall power level of the two (2) engines are si milar). In future studi es, where there is a

quantifiable difference in NVH or other char acteristics between the base case and the

new technology, the components required to a ddress 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 fro m the base configuration to the new

technology configura tion 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 consid eration, as describe d 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 th e CBOM are identified as requiri ng 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 circ umstances, the systems, subsystems, and

components under comparison, between the base and new technol ogy configurations,

will be different in variety of ways: part ex istence, 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 a nd/or OEM design a nd/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 differentia l costs between the ne w and base technology

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

technology. Typically base t echnology 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 substitute d for some of the existing hardware being evaluated.

These advanced technologies, through improve d 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 id entified 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 reduc tions in maturing technologies.

The Quote Assumptions section provides the cost analysis ro admap 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 tr eated as a “buy”, with surrogate costs

pulled from an applicable database.

# 3-3 2) “Marketplace Validation” identifies whic h components should be cross-checked

with market place data.

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

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

other.

4) “Component Information Requires Assump tion 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 a ssociated 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 w ould exist in the CBOM

as a complete assembly, would require disassemb ly 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 inform ation is used to he lp 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 comp lexity characteristics associ ated 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 es tablished (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 info rmation, from the P-flow s, into standardize

quoting worksheets. Supporting these two (2) pr imary 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 manuf acturing a product (e.g.

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

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

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

the turbocharger (unless consider ed 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 pro cess steps involved for a given manufacturing

process, having key informati on (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 abunda nt number of detailed P-flows becomes a

considerable advantage. For this cost anal ysis Design Profit® soft ware is utilized for

producing and managing the process flows. In formation regarding th e details of Design

Profit® software will be covered in the next section.

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

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

worksheet, referred to as the Manufactu ring Assumption and Quote Summary (MAQS)

# 4-2 worksheet, is essentially a modified gene ric 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, requi red in the manufacturi ng of a turbocharger

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

separate MAQS worksheet deta iling 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 feedi ng into the MAQS worksh eet, data is also

automatically linked in from the various costing database s. More discussion on the

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

4.2 Serial and Parallel Manufact uring Operations and Processes



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

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

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

considered serial operations within the brac ket welding process. Conversely, parallel

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

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

simultaneously.

A process is defined as one (1) or more operati ons (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, tu rning a check valve body on a single spindle,

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

process is where different operations (s erial 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 ch art 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 operati ons and processing). The Ma nufacturing Assumption section

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

and processes, into mass production operati ons and processes, is captured.

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

parts together; each operation on average ta king approximately te n (10) seconds to

# 4-3 complete. In a serial process (analogous to single, standalone work cell, manned by a

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

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

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

following scenarios could be evaluated (Not e rates and assumptions applied below are

fabricated for this example only):

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

operation in parallel.

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

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

parts/hour = $1.25/part

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

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

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

automated operations, 5 serial manual operations.

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

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

parts/hour = $0.42/part

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

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

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

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

automation offsetting higher manual assembly costs.

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

molding, stamping, die casting, selected sc rew machining) the manufacturing assumption

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

limited to determining the total number of pi eces of equipment required for the defined

volume.

Figure 4-1 illustrates the fundamental steps incorporated into the cost methodology.4-4Figure 4-1: FundamentalSteps in Costing Process1. SelectComponentAssembly,Subsystem, and /orSystem, for costanalysis3. DevelopProcess Flow Charts(Also referred to as Process Maps)During all levels of the teardown, process flowcharts capturing every manufacturingoperation are generated, including all keyvariables associated with each operation.Examples of the operations and part details include:> operation description, equipment specification, cycle times,material composition/specification, component geometry, componentmass, etc.Tools used to create Process Maps:> Design Profit® Software using Lean Design® Module> Munro & Associates Cost Estimator Model/Tools4. PopulateStandardized Quote Worksheets - Two Main Functional Sections(Also referred to as Manufacturing Assumption and Quote Summary (MAQS) worksheet)Manufacturing Assumptions(Section D of MAQS)Using the data generated from the ProcessFlow Charts, multiple calculations areperformed establishing the massproduction manufacturing assumptions.Examples included the following:> OEM and Supplier classifications are selected, based oncomponent type and processes, establishing the applicable markup rates> Serial operations are combined into parallel operations whereapplicable> Operations, both serial and/or parallel, are grouped into highvolume parallel processes where applicable.> Equipment numbers calculated to support capacityrequirements> Final equipment selection and associated burden rates areestablished> Calculate number of operators required to support definedmanufacturing process> Piece per hours calculatedQuote Summary(Sections B,C,E & F)Using the data generated in theManufacturing Assumption Section of theMAQS, along with data from the CostingDatabases, a net component/assembly costimpact is calculated.Information used in final calculations includes thefollowing:> Calculated pieces/hour> Material specification, quantity, and price/pound> Labor Classification, number of operators, and cost/hour> Burden Classification, number of machines, and cost/hour> OEM/Supplier Classification, percent of total manufacturingcosts> Packaging Container, cost per container, number of parts percontainerCosting Databases SupportProcess Mapping and Quote Worksheet Phases of Cost AnalysisFive (5) Databases storerates for all eight cost elements used within the cost analysis: Material, Labor, Burden, Mark-up (End-itemScrap, SG&A, Profit, and ED&T) and Packaging2. ConductControlledTeardown Process6. Roll Upcosts fromMAQS AssemblyWorksheetsinto NetIncremental SubsystemCosts7. Roll UpeachIncremental SubsystemCost into a NetIncremental SystemCost5. Market Place CrossCheckon SelectedAssemblies throughsolicitation of IndustryExperts

# 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 pr ocess maps, for the cost analysis. The Design

Profit® software consists of several modul es 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 M unro & Associates, Inc.

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

to mapping manufacturing operati ons and processes, providi ng 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 proj ect utilizing the exact same

databases. This further ensures consis tency 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 represen tation of the product through the use of

symbology depicting various a ssembly and manufacturing pro cesses. Figure 4-2 is a

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

product, process and operation metrics. Ther e 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 sym bol examples and associated descriptions.

Each symbol is generate d 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, machin e operations, etc., which provide the basic

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

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

a screenshot of a part input screen.

The majority of manufacturing information/ specifications uploa ded during the mapping

process are acquired directly from pre-es tablished internal libraries/databases

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

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

analysis studies.

In addition to manufacturing information inpu tted 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. injecti on molding, stamping, die casting). More

details on these external cost estimati ng models are covered in Section 4.5.

# 4-6 Design Profit® uses a combina tion of automated testing a nd dedicated developers who

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

algorithms in Design Profit® ha ve gone through scrutiny over th e 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 st andard labor rates,

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

repeatability and consistency in analysis. Desi gn 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®.4-7Figure 4-2: Screen Shot of Process Mapping Using Design Profit® Software

# 4-8 Figure 4-3: Property Window for a Pa rt Symbol Used in Process Mapping

4.4 Teardown Process Overview



# The teardown methodology utilized for the analys is 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 a nd mapping them in the Design Profit®

software. This provides a means of dete rmining when/where various components are

# 4-9 assembled and to what content level, pr oviding insight to diffe rentiate 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 leve l of teardown commences. As with the

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

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

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

deltas are disassembled down to individua l 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 disassemb led 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 data bases and costing tools are used to feed

essential data into Design Profit® Maps. Th ese 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 indi vidual 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, equipm ent size, number of cav ities per tool). This

is followed by capturing the secondary proc esses 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 ma nufactures will cast/mold in the material

properties. For components which are not mark ed, 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 s till materials which cannot be identified a

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

supplier community are contacted to es tablish 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 th e 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 t ypically utilized when there are internal

hollow sections formed by cores. A semi-p ermanent 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 out side 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 vari ous cost estimating models,

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

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

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

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

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

thickness, number of bends, number of punc hed 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 fo rmulas to establish the output results. The

fixed formulas also take into account various material and processing specifications

including material density, tens ile strengths, thermal diffusiv ity, injection pressures, die

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

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

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

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

and extruded), and steel/iron (casting, forg ing, 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 va lidation process to ensure the results are

reflective of current technologies and known co sts of components. An example of this

process would be validation of the injecti on molding module. Thre e (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 th at 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.4-11Figure 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 thr oughout the costing exercise. These secondary

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

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

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

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

the cycle time driver.

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

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

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

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

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

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

RTV is based on seconds per in ch. 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.4-13Figure 4-5: Operations Library – Design Profit® Database4-14Figure 4-6: Tool Library- Design Profit® Database4-15Figure 4-7: Material ModificationLibrary – Design Profit® Database4-16Figure 4-8: Fastening Library - Design Profit® Database

# 4-17 Figure 4-9 is a sample excerpt displaying th e 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 th e OEM and its’ assembly to the vehicle is

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

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

the OEM is the assembly of the various pa rts 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 w ith the appropriate burden rate being selected from the

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

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

casting as its primary manufactu ring method. To establish th e 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 ra w 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 in ches), part weight after machining (0.4733

pounds), number of planes with die lock featur es (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 associat ed 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 th e appropriate burden rate associated with

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

time (2.4 sec) cooling time (60.36 sec) rese tting 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.4-18Figure 4-9: Example Illustrating the Various Levels Associated with Process Mapping a Vacuum Pump Base SupportCasting ProcessMachining ProcessSupplierAssemblyLaborOEMAssemblyLabor

# 5-1 

# 5 Cost Model Overview

The cost parameters considered in determ ining 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 co st (TMC), mark-up costs and packaging

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

cost impact to the OEM (gen erally, the automobile manufac turer). Figure 5-1 shows all

the factors contributing to un it cost for supplier manufactu red components. Additional

details on the subcategories are discu ssed 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,

warrant y, 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 – Cos ting 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 Reta il Price Equivalent and Indirect Cost

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

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

.

Shipping Costs are those required to transpor t a component between dispersed

manufacturing and assembly locations, includi ng any applicable in surance, tax, or

surcharge expenses. Shipping costs between T2/T 3 and T1 suppliers ar e 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 fi xture costs required to manufacture a

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

stamping dies, weld fixtures, assembly fixt ures, dedicated assemb ly and/or machining

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

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

IC multiplier.

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

manufacture parts. Investment costs in clude manufacturing plants, manufacturing

equipment (e.g. injection mo ld machines, die cast mach ines, machining and turning

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

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

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

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

investments expenses are accounted for th rough manufacturing overh ead 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 asso ciated with a vehicle specific application

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

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

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

the OEM, the product developmen t 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 a nd Mark-up), in the supplier unit

cost model defined in Figure 5-1 

# includes considerations fo r shipping, investment and

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

OEM Unit cost model via the TMC. Shippi ng, tooling and produc t 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 /Assemb ly Cost Impact to OEM” is defined as

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

assembly differences, between the ne w and base technol ogy 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 produc tion, 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 transporta tion, 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. Th e OEM’s indirect costs, however, are not included and must

be determined and applied sepa rately to obtain total manufactur ing costs. These indirect

costs are beyond the scope of this study and ar e 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 th is section is taken from that report.

The RPE/IC report provides a new calculati on 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 reve nue to direct manufacturing cost; put another

way, it is the ratio of indirect costs plus pr ofit to direct manufactu ring costs. It is an

average over all the activities of a manufac turer. 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 compone nts of indirect costs that are likely to be affected by

vehicle modifications associ ated with environmental regulation. A range of IC

multipliers are developed that 1) account for d ifferences 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 diffe rences between the short- and long-run IC

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

decrease over time. R&D expe nditures also vary greatly ov er the level of technology

complexity, as does the need for dealer s upport. To use the mu ltipliers in the RPE/IC

# 6-2 report, analysts can start by assessing the degree of compl exity of the new technology

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

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

role of indirect cost contributors for the ne w 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 subcate gories, which make up the unit costs for all

components and assemblies in the analysis.

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

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

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

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

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

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

Appendix E.1-E.6.

The model allows for updates to the cost el ements which automati cally 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 upda tes the Manufacturing Assumption Quote

Summary (MAQS) worksheets. T hus 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 a ssociated with each database to project

changes from the baseline cost da ta. 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) fe ature. The AAF feature is basically a

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

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

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

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

rate value in the database from 2008 to 2015 lo ads the new dataset; a ll cost sheets are

automatically updated with the 2015 labor projections.

Additional details are provided for each database in the following sections.7-2Figure 7-1: Illustrates the change in Labor Rates between2008 and 2015, Assuming a Negative 5% Annual Adjustment Factor(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 anal ysis. The information related to each

material listed includes the material name, st andard industry identifi cation (e.g. AISI or

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

consumption rates, and s ource references. The prices reco rded 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 follo ws. Figure 7-2 and Figure 7-3 provide

the price data for significant material s identified in the cost study analysis.

# 7-4 Active Rate



# 2008

A. CARBON & ALLOY STEELS (SAE1000-90 0

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, Coi l 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 resistan ce 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

J. C o pper A llo ys F . P o wder M etal E. A luminum A llo ys

M . Q. Thermoplastics

R Thermosets.

S. Thermoplastic Elast. P . 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, Injec t 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, esterbased AU 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

J. C o pper A llo ys F . P o wder M etal E. A luminum A llo ys

M . Q. Thermoplastics

R Thermosets.

S. Thermoplastic Elast. P . 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 volum e 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 th e 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 re adily available, and the part

can be obtained from any number of compe titive molding companie s that regularly

manufacture these types of components. A V iton® fluoroelastomer engine seal, on the

other hand, is specified as a low annual consum ption 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 fo r its excellent heat and chemical resistance,

and is used sparingly for certain engine e nd-use applications. For case study #0101, only

material pricing corresponding to high a nnual volume consumption was considered.

7.2.2 Material Selection Process



# The materials listed in the database are resins and ferrous and non-ferr ous 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 identif ication. 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 id entified, information pub lished in print and on

the web is researched, or primary manufactur ers and experts within the Tier 1 supplier

community are contacted to estab lish credible material choices.

The specific application and the part appearance play a role in mate rials identification.

Steels commonly referred to as work-hardena ble 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 na rrow 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, fo rged components typically have a smoother appearance to

the grain whereas cast component s have a rougher finish, especially in the areas where

machining is absent. Castings also usua lly display evidence of casting flash.

The component application environment will also help determine material choice. There

are, for example, several conventional duc tile 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 e ngines. This is due to high temperature,

thermal cycling, and corrosion resistance dema nds associated with elevated exhaust gas

temperatures in turbocharged engines. Therefore understa nding 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 th e database is derived from various sources of publicly

available data from which histor ical trend data can be derive d. The objective is to find

historical pricing data over as many years as possible to obtain the most accurate trend

response. Ferrous and non-ferr ous alloy pricing involves inte rnet searches of several

sources, including the U.S. Geological Surv ey (USGS), MEPS (previously Management

Engineering & Production Services), Metalp rices, 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 obtai ned from sources such as Pl astics News, Plastics Technology

Online, Rubber and Plastics Ne ws and IDES (Integrated De sign Engineering Systems).

Several other sources are used in this re search as outlined in the database.

Though material prices are often published for st andard materials, prices for specialized

material formulations and/or those having a nonstandard ge ometric 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) a pproaches are used:

industry consultation a nd composition analysis. In cases such as Ni-Resist cast iron,

which has several different possible pre-proc essed heat treatments, consultation with

manufacturers of the component or similar components is required.

# 7-8 Obtaining prices for unknown proprietary mate rial compositions, such as powder metals,

necessitated a standardized industry approach. In these cases manufacturers and industry

market research firms are consulted to pr ovide 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 th icknesses. Any specified nonstandard sheet or plate thickness requires additional mill runs and must be priced

accordingly. In this case, price estim ations from consulta tions with industry

manufacturers in conjunction with similar mate rial 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 form ulations; however prici ng is not published for

every variation. This variation is significa nt since many manufactures can easily tailor

resin filler type and content to serve the specif ic application. Cons equently, the database

has been structured to group re sins 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 groupi ngs 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 fu ture material prices, there are statistical

methods, such as regression analysis, to help predict expected pr icing outcomes based on

past trends. Price movements can be grea tly 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 a nomalies, 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 lin e applied to historical 304 stainless steel

prices. Other trend line plo tting 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 ev aluated to establish the best fit line and

corresponding projection. Ho wever, it should be noted that, for the case study presented

in this report, a sensitivity an alysis 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 ma terial mass, beyond the final part weight,

required to manufacture a component. For exam ple in an injection molded part, the inprocess scrap is typically created from the de livery system of the mo lten 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 ca n 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 th e process of creating the part features.

Generally, material removed during the various machining processes is sold at scrap

value. Within this cost an alysis 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 el ement within mark-up and will be discussed in more detail

within the mark-up database section (Secti on 6.5). Although it is worth reiterating here

that in-process scrap only covers the a dditional 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 esta blished 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 seal s (gaskets, o-rings). However, in certain

cases more value-added com ponents are considered purchased when sufficient data

existed supporting their cost as a commodity, that is, where compe titive or other forces

drive these costs to levels on the order of thos e expected had these parts been analyzed as

“make” parts.

Purchased part costs are obtained from a va riety of sources. Th ese include FEV and

Munro team members’ cost knowledge, surroga te 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, prim arily 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 a nd vehicles. All labor rates referenced

throughout the cost analysis are referen ced from the established Labor Database.

The labor classification format of the databa se is created using the same methodology as

the Bureau of Labor Statistics (BLS). Furthe r, the core labor wage data used throughout

the study, with exception of fri nge and wage projection para meters, is acquired from the

BLS.

The Labor Database is broken into (2) tw o primary industry sections, Motor Vehicle

Parts Manufacturing (supplier base) and Moto r Vehicle Manufacturing (OEMs). These

(2) two industry sections corre spond to the BLS, North Amer ican Industry Classification

System (NAICS) 336300 and 336100 respectively. Within each industry section of the

database, there is a list of standard produc tion 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. Ever y production occupation listed in the Labor

Database has a calculated labor rate, as discussed in more detail below.

Labor rates for 2008 establish th e reference baseline from which projected labor rates can

be developed. An “Annual Ad justment Factor” is used to account for labor rate

projections. The labor rates ca n be modified for each produc tion occupation, or for the

industry as a whole.

7.3.2 Direct Versus Total Labor, Wage Versus Rate



# Each standard production oc cupation 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 High lighting Occupation Cl assification Codes,

Descriptions, and Mean Hourly Wages

Only “direct” production occupations are listed in the database. Team assemblers and

forging, cutting, punching, a nd press machine operators are all considered direct

production occupations. Ther e are several tiers of ma nufacturing personnel supporting

the direct laborers that need to be acc ounted for in the total labor costs: quality

technicians, process engineers, lift truck driv ers, millwrights, electricians, etc. A method

typically used by the automotive industry to account for all of thes e additional “indirect

labor” costs, and the one chosen for this cost analysis, is to calcula te the contribution of

indirect labor as an average percent of dire ct 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, rath er than labor rate da ta. In addition to

what a direct laborer is paid, there are se veral additional expenses the employer must

cover in addition to the employee base wage . This analysis refers to these added

employer expenditures as “fring e”. Fringe is applicable to all employees and will be

discussed in greater detail below.

It should be noted that the BLS motor ve hicle and motor vehicle parts manufacturing

(NAICS 336100&336300) labor rate s include union and non-union labor rates, reflecting

the relative mix of each in th e 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) contributor s 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 classifi cation would include injection mold press operators, die cast

press operators, heat treat equipment opera tors, team/general assemblers, computer

numerical controlled (CNC) machine opera tors, 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 i ndirectly 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 sele cted 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 cont ribution 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 secto r, occupations are sorted (using SOC

codes) into one (1) of the four (4) ca tegories, 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 require d to repair and maintain

manufacturing equipmen t 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 expe nses captured as pa rt of fringe include

company medical and insurance benefits, pension/retirement benefits, government

directed benefits, vacation and holiday be nefits, 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 supp lier manufacturing, and 160% for OEM

manufacturing. The supplier ma nufacturing fringe rate is ba sed on data aquired from the

BLS; Employer Costs for Employee Compen sation Historical Listings, March 2004 -

2009. Using the average 2007/2008 manufacturi ng 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 Americ an UAW OEM hourly wage and total

compensation rate of $28.18 and $73.21 respectiv ely, a rate of 160% was calculated.

Additional details on these calculations can be found in the labor database.

Taking the four (4) contributor s 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 I ndirect 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 percen t of direct, indirect and MRO labor:

Fringe = ($15.15 + $10.00 + $3.48) * 0.52 = $14.88/hr

Lastly, the labor rate for injection mold ing 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 occupa tions and corresponding

total labor rates are shown. Similar ca lculations are made for every production

occupation classification found in the Labor Database.7-16Figure 7-7: Labor Database Excerpt Showing Contributors to Total Labor Ratefor Various Direct Labor Occupations

# 7-17 7.4 Manufacturing Overhead Database

7.4.1 Overview



# The Manufacturing Overhead Da tabase contains several manufacturing overhead rates

(also sometimes referred to as burden rates, or simply burden) associ ated to various types

of manufacturing equipment, that are re quired to manufacture automotive parts and

vehicles. With material and labor costs, it forms the total manufac turing cost (TMC) to

manufacture a component or assembly, accoun ting for workers, supervisors, managers,

raw materials, purchased parts, production f acilities, 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 overhea d, and so manufacturing overhead rates are

categorized according to primary manufacturi ng processes and the a ssociated equipment

as follows:

1. The first tier of the Manufacturing Overhe ad Database is arranged by the primary

manufacturing process groups (e.g., therm oplastic molding, thermoset molding,

castings, forgings, stamping and forming, pow der metal, machining, turning, etc.)

2. The second tier subdivides the primary ma nufacturing 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 Manufactur ing Overhead Database is shown in

Figure 7-8. In this example, the leve ls of complexity in CNC equipment are

described and assigned an ‘Active Rate’, wh ich 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 a dded 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 A uxiliary 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 A uxiliary 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 A uxiliary 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 A uxiliary 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 A uxiliary 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 A uxiliary 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 A uxiliary 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 A uxiliary 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 add ed 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 Primary Processing Equipment Secondary Process Equipment Cat. Item Burden Title

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

J. Grinding F . P o wder M etal 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 establis h 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 manuf acturing 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 - gene ral, 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 fi xed and variable costs.

Generally, the largest contribution to th e fixed burden costs are the investments

associated with primary and process support e quipment. 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 f acility for a pre-defined period. This value is then divided

by either the total direct labor cost, the tota l direct labor hours, or the total machining

hours.

Since this cost analysis assu mes that all production is in No rth 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 dir ect labor hours versus

machine hours, making a machine-based burden rate more applicable for this cost

analysis. Thus all burden rate s contained in the Manufacturing Overhead Database are

considered machine based burden rates.

Depending on the mix of equipment, proce sses, and product vari ation at a given

manufacturing facility, a corporati on 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, regardle ss 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 fa cility. For example,

stamping welding, and general assembly w ould each be assigned a unique burden rate.

For this cost analysis the majority of the co sting is done using activity based burden rates.

However, for a few components where ther e 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 availa ble data on manufacturi ng overhead rates for

the industry sectors included in this analysis , overhead rates have been developed from a

combination of internal knowledge at FEV a nd Munro, supplier netw orks, miscellaneous

publications, reverse costing exercise s and “ground-up” ma nufacturing overhead

calculations.

For ground-up calculations, a generic “Manufac turing Overhead Calculator Template”

was created. The template consists of ei ght (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 H ourly Burden Rate. An exam ple of the template can be

found in Appendix E.4 illustrating the hourly burden rate calcula tion for a 500 ton (T)

injection mold machine. To assist in the discussion of th e various sections of the costing

template, input and calculated values for th is same example are captured below in

parentheses.

The General Manufacturing Overhead Informa tion section, in add ition to defining the

burden title (Injection Molding, Medium Size and/or Moderate Complexity) and

description (Injection Moldi ng Station, 500T Press), also defines the equipment life

expectancy (12 years), yearly operating capacity (4700 hours), operation efficiency

(85%), equipment utilization (81.99%) and borro wing 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) associ ated with equipment depreciation over the

defined life expectancy. A straight-line-deprec iation method, with zero end of life value,

is assumed for all equipment. Included in th e cost of the base equipment are several

factors including sales tax, freight, installati on, insurance, maintenance-parts, etc.

The Process Support Equipment section (e .g. Chiller, Dryer, Th ermal Control UnitMold), similar to the primary process equipment section, calculates the annual expense

($6,121) associated with proce ss support equipment depreciation.

The General Plant and Office Hardware /Equipment section assigns an annual

contribution directed towards covering a por tion of the miscellaneous plant & office

hardware/equipment costs (e.g. millwright, electrician, and pl umbing tool crib,

production/quality communication, data tracking and storage, general material handling

equipment, storage, shippi ng and receiving equipm ent, general quality lab equipment,

office equipment). The contri bution expense ($2,607) is calc ulated 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), a nd general plant and

office hardware/equipment ($6,374). The gene ral plant and office hardware/equipment

floor space allocation is a calculated percenta ge (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 de preciation costs, prope rty taxes, property

insurance, general facility maintenance, general utilities, etc.

The Utilities section calculates a utility expe nse per hour for both primary equipment

($9.29/hour) and process support equipmen t ($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 ga s at $0.00664/cubic foot, and water at

# 7-22 $0.001/gallon. General plant and office hard ware/equipment utility expenses are covered

as part of the facility cost addr essed above (i.e., $11.50/square foot).

The Plant Salary section estimates the contri bution of manufacturing salaries (e.g. plant

manager, production manager, quality assuranc e 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 manufacturi ng facility sizes and corresponding salary

payrolls to choose from; each has a calculat ed salary cost/square foot. Based on the

combined square footage utilization of the primary, process suppor t, and general plant

and office equipment, an annual salary c ontribution cost is calculated ($6,625).

The final section, Calculated Hourly Burden Rate, takes the calculated values from the

previous sections and calcula tes the hourly burden rate in three (3) steps: (1) 100%

efficiency and utilization ($30.54/hour), (2) use r-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 gr oups (e.g. injection mo lding, aluminum die

casting, forging, stamping a nd 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 manufacturi ng overhead review. Fo r any given category,

there will often be a range of equipment si zes 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 maintain ing high costing resolution.

In the example of the 500T injection moldi ng press burden rate, the calculated rate

($38.79) was averaged with three (3) othe r 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 calc ulated burden rate of $50.58/hour is used in

applications requiring injection moldi ng presses in the range of 400-800 tons.

As discussed, multiple methods of arriving at burden rates are us ed 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 validati on 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 re quirements, or some other unique feature

dictates a special rate. In cases where a ma rk-up rate is “flagged” within the costing

worksheet, a note is included which describe s 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 allowa nce, (2) SG&A expenses, (3) profit, and

(4) ED&T/ R&D expenses. Additional details fo r each subcategory are discussed below.

The layout of the Mark-up Database is sim ilar to the Manufacturi ng Overhead Database

in that the first tier of th e Mark-up Database is arrange d by the primary manufacturing

process groups (e.g., thermoplastic processing, thermoset processing, casting, etc.). The

second tier subdivides the primary manufacturi ng process groups into primary processing

equipment groups (e.g., thermoplastic processi ng is subdivided into injection molding,

blow or rotational molding, a nd pressure or vacuum form molding). The third and final

tier of the database, increases the resoluti on of the primary proc essing 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 investme nts, which in turn, will have a direct

correlation to mark-up rates.

For example, a small, low co mplexity Tier 2/Tier 3 injection molding facility will

generally have less in-process scrap (as a re sult of defective parts and/or destructive

testing), less corporate overhead, less invest ment risk, and less e ngineering, design and

testing support than a large, high complexity Tier 2/Tier 3 injecti on molding facility, as

illustrated in Figure 7-9.7-24Figure 7-9: Mark-up Database Excerpt Highlighting the Rate Differences ( End Item Scrap, SG&A, Profit, and ED&T), for Three (3) Levels ofInjection 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 Ma nufacturing 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 c over the projected manufacturing

fall-out and/or rework costs associated with producing a partic ular component or

assembly. In addition, any costs associated with in-pro cess destructive testing of a

component or assembly would also be covered by this allo wance. As a starting point,

scrap allowances were estimated to be betw een 0.3% and 0.7% of the TMC within each

primary manufacturing processing group The actu al assigned value, fo r 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 i ndustry expert produces more

reliable estimates for scrap allowance associ ated with a generic manufacturing process

(e.g. 5% for sand casting, investment cas ting), the Mark-up Database is updated

accordingly. In cases where the manufacturi ng process is consider ed generic, but the

component performance requirements drive a higher fall-out rate (e.g. 25% combined

process fallout on turbocharger turbine wheel s), then the scrap mark-up rate would only

be adjusted in the Manufacturing Assump tion 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 Exec utive 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 adve rtising expenses

• Corporate travel expenses

SG&A, like all mark-up rates, is an applied percentage to the Total Manufacturing Cost.

The default rates for th is 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 pr ocessing equipment as shown in Table 7-2.

To support the estimated SG&A rates (whi ch are based on generalized OEM data),

SG&A values are extracted fro m publicly traded au tomotive 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 th is cost analysis, it is assumed that the

technology being studied is ma ture from the development and competition standpoint.

These assumptions are reflected in the c onservative 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 generaliz ed 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 "impleme ntation ready" technology and in tegrate 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 e nhance an existing) component/system

technology, is often inde pendent of a specific vehicle app lication. In contrast to ED&T,

pure R&D costs are very difficult to pred ict and are very ri sky 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. Fo r 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 se lected. 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 re port. Table 7-1 provide s some examples of

Tier 1 automotive supplier SG&A and ED&T /R&D rates. These rates are based on

world wide operations including auto motive 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 Manufacturi ng 4.8% 3.8% 4.0% 2.5%



# Source: 2008 Company Annua l Financial Reports

Royalty fees, as the result of employing intelle ctual 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 captu re 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, intellect ual property is always treated as though it is

purchased from a second entity.

See Table 7-2 for applicable mark-up rate s 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 a pplied regardless of the

primary manufacturing pro cess 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 si ze 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 st andard 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 classifica tion system is based on a component,

assembly, or system complexity ranki ng. 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, stam ping, 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 ma rk-up rates to a given component/assembly

are as follows:

Step 1. Primary manufacturing process a nd equipment groupings are pre-selected

as part of the process to identify the manufacturing overhead rate.

Step 2. Manufacturing facilities are id entified as OEM, T1 or T2/T3 (this

identification process is discussed in mo re detail in the Manufacturing Assumption

& Quote Summary worksheet section).

Step 3. The best-fit mark-up rate is se lected 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 comple xity are considered as independent

parameters when reviewing a compone nt and the equipment capabilities (with

priority typically given to ‘complexity’)

Table 7-3 is an example of mark-up rate cl assifications based on size and complexity

combinations for some typical stampings, ca stings, 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 Cl assification 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 standa rdized packaging options available for

developing packaging costs for components and assemblies. In the cost analysis only

packaging costs required to transport a co mponent/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 shi pping expenses. Tier 1 markup on incoming Tier 2/3 parts and purchase part s are discussed in more detail in Section

8.

All core packaging items (containers, pallets, to tes, etc.) referenced in the database are

considered returnable dunnage. Internal pack aging (tier pads, dividers, formed trays,

etc.) are also considered return able with the exception of a fe w items that are expendable.

The cost to clean and mainta in returnable dunnage is a ssumed 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 limite d to a few standard types and sizes to

minimize complexity. In general, everythi ng is tailored towards fitting onto a standard

automotive pallet (as specifi ed by the Automotive Industry Action Group), which has

exterior dimensions of 48 by 45 inches a nd 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 guidelin e 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 stac ked 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, shap e, fragility, and cleanliness,

one (1) of the packaging options above ar e selected, along with an internal dunnage

scheme. If it is deemed impractical to p ackage the component w ithin one (1) of the

primary options, a new package style is crea ted and added to the Packaging Database.

Once the primary packaging type and associ ated internal dunnage are selected for a

component, the assumptions along with the costs are entered into a Manufacturing

Assumption Quote Summary (M AQS) worksheet. In the M AQS worksheet, packaging

costs along with volume assumptions, pack dens ities, stock turn-over times, program life,

packaging life, and interest expenses are used to calculate a cost-pe r-part for packaging.

Section 9 provides more details on th e calculation of packaging costs.

7.6.3 Support for Costs in Packaging Database



# Primary pallet and container co sts are acquired from either Tier 1 automotive suppliers or

from container vendors. In some cases, sca ling 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 a nd processing estimates. When tooling costs are required for

packaging, the value of that tooling is adde d to the total pallet container piece cost, as

calculated in the MAQS worksh eets. The total value is th en amortized to calculate a

cost-per-part for packaging.

# 8-1 

# 8 Shipping Costs

In the cost analysis, shipping costs are account ed 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 tran sportation, are alwa ys considered freight

on board (FOB) the shipper’s dock. Belo w are the four (4) shipping scenarios

encountered in the cost analysis and how each case is handled.

The first two (2) cases, OEM a nd supplier inner company trans portation, 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 tran sportation equipment and/ or subcontract this

service out. In either case the expe nse is binned to manufacturing overhead.

The third case is Tier 1 shipments to an OE M facility. As stated a bove the shipments are

FOB the shipper’s dock and thus the OEM is re sponsible for the shippi ng 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 part s from Tier 2/3 suppliers. The mark-up

covers many costs including the shipping expens es 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 cont ent 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 chos en 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 Quot e Summary (MAQS) worksheet is the

document used in the cost an alysis 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 wo rksheet for any component or assembly.

Additional details on the inform ation which flows into, and out of the MAQS worksheet

are discussed in more detail below. Sec tion 11 discusses how MAQS worksheets are

uploaded into subsystem and system su mmary templates to calculate the net

component/assembly cost impact to the OEM.

The fundamental objective of the MAQS work sheet is similar to a standard quoting

template used by the automotive industry. However the format has been revised to

capture additional quote details and manufactu ring assumptions, improve on transparency

by breaking out all major cost elements, and accommodate variable data inputs for the

purpose of sensitivity assessments. These feat ures are discussed in more detail below.

For a given case study, all Ti er 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 shi pped to a Tier 1 supplier, a separate MAQS

worksheet is created for grea ter transparency. These T2/3 MAQS worksheets are linked

to T1/OEM MAQS worksheets, which in tu rn are referenced back to the CBOM.

9.2 Main Sections of Manufactur ing Assumption and Quote Summary

Worksheet



# At the top of every MAQS worksh eet 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 worksh eet back to the applicable CBOM. The

primary quote assumption section provides the ba sic information needed to put together a

quote for a component/assembly. Some of the parameters in the quote assumption

section are automatically referenced/linke d throughout the MAQS worksheet such as

capacity planning volumes, product life span, a nd OEM/T1 classificati on. The remaining

parameters in this section including fa cility locations, shi pping methods, packing

specifications, and component quote level are manually considered for certain

calculations. Included in Appe ndix F.1 is a sample MAQS worksheet identifying all the

major sections.

Two (2) parameters above whos e 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, complex ity, 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 data base into the MAQS worksheet. For

example if “T1 High Assembly Complexity” is typed into the input cell, the following

values for mark-up are pulle d into the worksheet: Scrap = 0.70%, SG&A = 7%, Profit =

8.0% and ED&T = 4%. These rates are then multiplied by th e TMC at the bottom of the

MAQS worksheet to calcula te 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 Asse mbly Complexity, Moderate Assembly

Complexity, Low Assembly Co mplexity) is based on the team’s knowledge of existing

value chains for same or similar type components.

Figure 9-1: Excerpt Illustrating Automate d 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 le vel of detail is captured in the MAQS

worksheet for a particular component/asse mbly, full quote, modification quote, or

differential quote. When the “full quote” box is checked off, it indicates all

manufacturing costs are captured for the co mponent/assembly. When the “modification

quote” box is checked off, it indicates only the changed portion of the

component/assembly, has been quoted. A diffe rential quote is similar to a modification

quote with the exception that informati on from both technology c onfigurations, 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 compar ed for cost, each head can ha ve 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, et c.) can be offset, and the differential cost

calculated in a single worksh eet. The differential quote method is typically employed

with those components with low differential co st 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, pos itioned 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 au tomatically loaded in to 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 va lue-added operations required to make a

component or assembly. For example, a high pr essure 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, mach ine). In the MAQS wo rksheet each of these

process operations has an individual line summarizing the manufacturing assumptions

and costs for the defined operation. For a cas e with two (2) defined operations per base

level component, plus two (2) subassembly a nd final assembly operations, there could be

as many as forty (40) define d operations detailed out in th e MAQS worksheet. For ease

of viewing all the costs associ ated with a part, with multip le value-added operations, the

operations are grouped together in the MAQS worksheet.

Commodity based purchased parts are also incl uded as a separate line code in the MAQS

worksheet. Although there are no supporti ng manufacturing assumptions and/or

calculations required since the costs are provided as total costs.

From top to bottom, the MAQS worksheet is di vided 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 Pro cessing and Assembly, (2) Purchase Part – High Impact

Items, (3) Purchase Part – Lo w Impact Items, and (4) Purcha se Part – Commodity. Each

quoting level has different rules relative to wh at 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 Pr ocessing and Assembly section are all the

assembly and subassembly manufacturing opera tions assumed to be performed at the

main OEM or T1 manufacturing facility. Included in manufactu ring 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 perfo rmed including mark-up calculations for those

components/operations consider ed 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 elem ents 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 comm odity based purchase pa rt costs are binned

to material costs. The cost estimating me thodology 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 le vel 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, reco rded in the four (4) quote levels, are

automatically added together to obtain the TM C. 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 seve n (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 wo rksheet is the packaging calculation, Section E

. In this section of the MAQS worksheet a p ackaging cost contributi on 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 fo r 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 in ternal 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 packag ing calculator is not used.

Figure 9-2: Example of Packaging Cost Calc ulation for a High Pressure Fuel Injector

9.3 Manufacturing Assumption and Quote Summary Detail Review



# Although simple in function, the MAQS work sheet appears rather complex due to the

amount of information imported, referenced, an alyzed, and exported. To help describe

this information flow into and out of th e 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, referenc e sources and output s ources of information

and data exchange associated with each task. In addition, key sour ces of interaction and

data exchanges have been identified with spec ial text formatting to help highlight these

key interaction sources. For ex ample 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 th e table. Lastly, in

the task description column, th e word “Enter” or “Automatic ally” 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 work sheet template as the cost study analysis

progressed. As such, the information show n in Appendix F.1, MAQS Worksheet Task

Reference Guide and accompanying MAQS work sheet 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 re vision level MAQS template features were

updated during the first cost analysis.

# 10-1 

# 10 Marketplace Validation

Marketplace validation is the process by wh ich individual parts, components and/or

assemblies are cross-checked with costing data devel oped by entities and processes

external to the team responsible for the cost analysis. This pr ocess occurs at all stages of

the cost analysis; special emphasis is pl aced on cross-checking in -process costs (e.g.

material costs, material selection, labor co sts, manufacturing overhead costs, scrap rates,

and individual component costs within an assembly).

In-process cost validation occu rs when a preliminary cost has been developed for a

particular part within an assembly, and th e 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 ma terials where available. If the discrepancy is still unresolved,

the team would rely on automotive supplier ne tworks, industry expert s, 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 analys is, mainly as a “big picture”

check. In general cross-checking final asse mbly costs are typically achieved through

solicitation of industry experts. The de pth of cross-checking ranges from simple

comparison of cost data on surrogate asse mblies to full Manufac turing 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 inducti on, air induction,

exhaust, etc.) as defined by the CBOM. A ll parts identified, w ithin the applicable

subsystem of the CBOM, as re quiring cost analysis, are entered into the CMAT. Also

both the base and new technol ogy configurations are include d in the same CMAT to

facilitate the differential cost analysis.

The cost inputs for the Subsystem CMAT ar e the MAQS worksheets. As discussed

previously, generally every component a nd 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 configur ation 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 ba se 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 component s or assemblies are pulled into

the same MAQS worksheet for differen tial cost analysis. In this case

the costs are binned to either the base or new tec hnology configuration

(case dependent) and the technology conf iguration showing zero costs is

highlighted yellow (i.e., “$ 0” or “$ - ”) in the CMAT.

The MAQS worksheets are automatically linke d to the CMAT templates to facilitate

automatic updating for assumption changes a nd/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 take n 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 In jection (DI). Included in Figure 11-1, is an overlay of the

Unit Cost Summary section, taken from the M AQS worksheet for the high pressure fuel

Pump, highlighting the link between the documen ts. For this particular Fuel Induction

Subsystem example, the Net Component Asse mbly Cost Impact to the OEM is $148.18,

for the new technology configur ation, and $40.84 for the base technology configuration.

# 11-2 Thus $107.34 ($148.18-$40.84) is th e pre-estimated cost impactto add DI over PFI. Preestimated indicating that ther e are other potentially cost factors for adding DI which are

not included in the Fuel I nduction Subsystem classificati on. For example additional

machining of the cylinder head for mounti ng the injectors would be an added cost

addressed in the Head Subsystem.11-3Figure 11-1: Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem Cost Roll Up for the Fuel InductionSubsystem - NewTechnology Configuration - Case Study #N0101Example showing Section F of the MAQS worksheet,for the high pressure fuel pump, uploading thesubsystem CMAT.11-4Figure 11-2: Excerpt from Subsystem CostModel Analysis Template Illustrating Subsystem Cost Roll Up for the Fuel InductionSubsystem - BaseTechnology 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 subs ystem 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 th e base and new tec hnology 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 li nked directly to the System CMAT supporting

automatic updates due to assumption changes and/or sensitivity studies.11-6Figure 11-3: Excerpt from System Cost Model Analysis Template Illustrating the Incrmental Subystem Cost Roll Up forCase Study #0101 - 2.4L I4, 16 Valve, DOHC, NA,PFI downsized to 1.6L I4, DOHC, Turbo GDI

# 12-1 

# 12 Operating and End-of-Life Costs

Some of the technologies be ing analyzed may involve a dditional maintenance or a

change in existing maintenance. Some ma y also involve additional vehicle scrappage

costs or salvage value. Thes e incremental costs and savings are evaluated and presented

separately from the new vehicle unit costs.

The maintenance and end-of-life cost calcula tions 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 engineeri ng knowledge of how the technology affects

vehicle operation.

2. Calculate the differential cost of the identified maintenance practice.

3. Calculate the number of corresponding ma intenance 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 differen tial 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 met hodology detailed in the previous sections, the first cost

study analysis was conducted: stoichiometric , gasoline direct injection (GDI) with

turbocharging on a downsized I4 engine, comp ared to an equivalent conventional I4

engine. The hardware chosen to represen t the new technology conf iguration 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 CM AT showing the increm ental cost impact

for each subsystem for Case Study #0101. For Case Study #0101, condensed versions of

all supporting MAQS worksheets can be f ound 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 wo rksheets, 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 An alysis 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 intellect ual 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 nece ssary to understand how sensitiv e 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 m odeled relative to 2008 dollars: supplier and

OEM labor cost -20%; OEM labor rate fri nge contribution reduced from 160% to 52%

(matching supplier rate); burde n cost -20%; material cost +/- 20%; mark-up +/- 20%.

Given the clear trends in North American ma nufacturing, only declin es were considered

for the labor and burden rates w ithin this sensitivity analysis. The percent change in cost

for each of these categories was modeled indepe ndently, 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 compone nts 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 cost s include a combination of raw materials,

material processing scrap, and commodity pur chased parts. The value of commodity

purchase parts, if excessive, can prove mislead ing relative to the contribution of each cost

element within the cost model. In case st udies which follow, grea ter 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 standa rdized cost models (e.g., the Total Manufacturing Cost

for a electromechanical device type “X” woul d have the predefined cost model - 35%

material, 15% labor and 50% burden). Becaus e surrogate costing da ta 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 la bor, burden, and somewhat higher material).

# 15-1 

# 15 GLOSSARY OF TERMS

Assembly: generally refers to a group of interdep endent components joined together to

perform a defined function (e.g. turbocha rger assembly, high pressure fuel pump

assembly, high pressure fuel injector assembly).

Buy: is the terminology used to identify thos e 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 pr esented. Typically

these types of parts are considered commod ity purchase parts havi ng industry established

pricing.

CBOM (Comparison Bill of Materials): is a system bill of materials, identifying all the

subsystems, assemblies and components associ ated with the technology configurations

under evaluation. The CBOM records all the high level details of the technology

configurations under study, iden tifies those items which have cost implication as a result

of the new versus base t echnology differences, documents the study assumptions, and is

the primary document for capturing input from the cross functional team.

Component: is the lowest level part w ithin the cost analysis. An assembly is typically

made up of several components acting together to perform a functi on (e.g. the turbine

wheel in a turbocharger assembly). Howe ver, in some cases a component can act

independently performing a func tion 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 pr ocess parameters for primary manufacturing

processes (e.g. injection molding, die cas ting, metal stamping, forging). Key

information calculated from the costing estima ting tools (e.g. cycle times, raw material

usage, equipment size) is inputted into th e Lean Design® process maps supporting the

cost analysis. The Excel ba se cost estimating models ar e developed and validated by

Munro & Associates.

Costing Databases : refer to the five (5) core databa ses which contain all the cost rates

for the analysis. The materi al 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, manufactur ing jobs (supplier and OEM), along with the

associated mean hourly labor rates. The manufacturing overh ead rate database contains

the cost/hour for the various pieces of manufacturing equipmen t assumed in the analysis.

A mark-up database assigns a percentage of ma rk-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, th e 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. Le an Design® uses a series of standardized

symbols, each base symbol representing a group of similar manuf acturing procedures

(e.g. fastening, material modifications, in spection). For each group, a Lean Design®

library/database exists containing standard ized operations along with the associated

manufacturing information and specifications for each operation. The information and

specifications are used to generate a ne t operation cycle time. Each operation on a

process flow chart is represented by a base symbol, operation desc ription, and operation

time, all linked to a Lean Design® library/database.

Make: is the terminology used to identify thos e components or assemblies as ones in

which a manufacturer would produce internally versus purchase. All parts designated as

a “make” part, within the analys is, are costed in full detail.

MAQS (Manufacturing Assumption and Quote Summary) worksheet : is the

standardized template used in the an alysis 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 documen ts 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 optim ization ideas with the hardware under

evaluation. These savings could potentially reduce or increase the differential costs

between the new and base technology conf igurations, 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, asse mbly, subsystem or

system. For components produced by the supplier base, the net manufacturing cost

impact to the OEM includes total manuf acturing costs (material, labor, and

manufacturing overhead), mark-up (end-item scrap costs, selling, general and

administrative costs, profit, and engineeri ng design and testing co sts) and packaging

costs. For OEM internally manufactured co mponents, the net manufacturing cost impact

to the OEM includes total manufacturing cost s 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 c ould be substituted in for some of the

existing hardware under evaluation. Thes e advanced technologi es, 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 technol ogy 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 manufactur ing variables, invol ved in manufacturing

products at any level (e.g. vehicle, sy stem, subsystem, assembly, component).

P-VCSM (Powertrain–Vehicle Cl ass Summary Matrix): records the technologies

being evaluated, the applicable vehicle cl asses for each technology, and key parameters

for vehicles or vehicle systems that have been selected to repr esent 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 interdepende nt assemblies and/or components,

required to create a functioning sub-subsystem. For example, the air induction subsystem

contains several sub-subsyste ms including the following: tur bocharging, 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 s ubsystem. 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, ai r induction, exhaust), as defined by the

Comparison Bill of Material (CBOM).

Surrogate part : refers to a part similar in fit, fo rm and function as the part required for

the cost analysis. Surrogate parts are sometim es used in the cost analysis when actual

parts are unavailable. The cost of a surrogate pa rt 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 t ogether to create a vehicle primary function (e.g. engine

system, transmission system, brake syst em, fuel system, suspension system).

# 15-4 System CMAT (Cost Mode l Analysis Template): is the document used to display and

roll up all the subsystem incremental costs associated with a sy stem (e.g. engine,

transmission, steering), as defined by the CBOMs.APPENDIXA.1 Powertrain-Vehicle Class Summary Matrix Excerpt – Case Study #0101EPA Contract: EP-C-07-069 WA1-3 A-1, Page 1 of 1APPENDIX B.1 Powertrain Package Proforma - Case Study #0101EPA Contract: EP-C-07-069 WA1-3 B-1, Page 1 of 1APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance UpgradesX02Assumed the engine mounts are of reasonable qualityforthe Base Engine (NA PFI). As such, no changes wouldbe required for Turbo DIX02A Bracket - Engine Mount, FrontX02 01 -N0101- 01 1MTNRX10A Bracket - Engine LiftX02 10 -N0101- 01 1MTNRX75A Bracket- Wire/Belt Guide (Front of Crank Damper )X02 75 -N0101- 01 1MTNRX80A Bolt- Bracket, Engine Mount, FrontX02 80 -N0101- 01 4MTNRB Bolt - Bracket, Engine Mount, Front of Crank DamperX02 80 -N0101- 02 1MTNRC Bolt - Lift EyeX02 80 -N0101- 03 2MTNR0301A. Shaft - Crank03 01 -N0101- 01 11 X XAssumption: both shafts are made from Micro-AlloyedSteel such as C38N2 or C38Mod(+Vanadium). Due toreduced stroke and overall crankshaft length expectcostreduction.Need to ensure additional features are equal betweenNew and Base such as Rolled Fillets.Potential for Base Engine Crank Shaft to be madefrom Nodular Cast Iron as cost save.NAX 02A Flywheel Assembly - EngineX03 02 -N0101- 01 12Single Mode Fly Wheel on Mini Cooper. Potentiallytwisting pulsations handled through Torque Convertertuning. Would not be able to tune out any degradation dueto bending vibration.May not need to consider for smaller displacements,but will be mandatory with higher displacement TurboDI Engines.Dual Mass Fly Wheel Required for DI Engine? Trackas cost Risk?NA03A Rod Subassembly - Connecting03 03 -N0101- 01 4A1 Bushing - Connecting Rod03 03 -N0101- 02 4MP-3 X XBushing required to accommodate higher loading at pin toconnecting rod interface.Connecting rod bushing typical may be replacedwith phosphate coated road end which is a newerprocess which offers less design margin. Whatis cost delta???A2 Rod - Connecting03 03 -N0101- 03 4MP-3 X XAssumption: both have forged connecting rods made fromeither C70 or 36MnVS4 Micro Alloy Steel or equivalent.The connecting rods are approx. same length for bothpackages, however Turbo DI rods have thicker crosssection to handle higher loads.To equalize the connecting rods for cost comparison,the rod length to crank radius (L/R) ratio should beassumed common for both designs. Ideal range isbetween 3-4; most production engines are between 3-3.6. The Chrysler GEMA engine is designed to use acommon connecting rod for all three engines onsame platform. Thus the L/R ratios are as follows:2.4L = 2.964, 2.0L = 3.471 and 1.8L is 3.968.Calculate cost impact assuming common MiniCooper L/R ratio.B Cap- Connecting Rod03 03 -N0101- 04 44 X XAssumption: both have forged connecting rods made fromeither C70 or 36MnVS4 Micro Alloy Steel.04<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesEngine Frames, Mountings & BracketsEngine MountingsHanging-up EyeEngine BracketsBoltingsCrank ShaftFlywheelsCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistenceConnect Rods (Assemblies:Connecting Rod, ConnectingRod Cap)Pistons (Assemblies, Including Pistons, Ring Packs,Piston Pins, Circlips)PART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEMCrank Drives 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 1 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XA Piston - Engine, Machined03 04 -N0101- 01 45 X X XLess mass, additional machining at piston crown andforpiston pin clips. Top ring groove anodized for improveddurability and reduction in the potential of microweldingthe top compression ring in the groove. Assume sameanti friction skirt coating on both New and Base Pistons.Post heat treat and machining premium on hypereutecticmaterial.Neither design has piston cooling channels.Benchmarking is split, for example BMW 3.0L DITurbo has cooling channels and the 2.0L GMEcotec does not. On a current Turbo DI project,FEV is evaluating if there is notable spark timingadvantage with the addition of piston coolingchannels.B Ring/Clip - Piston Pin Retainer03 04 -N0101- 02 86 XClips required for dual bearing slip fit design ofpin toconnecting rod & piston.C Pin- Piston03 04 -N0101- 03 47 X XAssume same material, Chromium Steel SAE 5115(16MnCr5). Quote mass difference only.D Compression Ring - Piston, Top03 04 -N0101- 04 48 XAssume that the Turbo DI will use a more durable, lowfriction ring pack versus base. For Example, topcompression ring, might be Silicon Manganese SpringSteel or Chrome Versus Cast or Nodular Iron. Coatingmay be Metallized Molybdenum versus a standardManganese Phosphate.Estimated to be Approx. $1.00 hit per ring pack (Top,Second and Oil Ring). Confirm with Tech. SpecialistE Compression Ring - Piston, 2nd03 04 -N0101- 05 49 XSimilar to Top Compression RingF Oil Ring SubassemblyF1 Spacer/Expander/Coil Spring - Oil Ring, Piston 03 04 -N0101- 07 410 XAssumption is higher end performing Oil Ring Assemblyon Turbo DI versus NA PFI.F2 Rail(s) - Oil Ring, Piston03 04 -N0101- 08 411 XAssumption is higher end performing Oil Ring Assemblyon Turbo DI versus NA PFI.X 80A Bolt -Connector Rod Cap to Connecting RodX03 80 -N0101- 01 812NRB Screw - Sensor Crankshaft to BlockX03 80 -N0101- 02 113NRC Bolt -Flywheel to CrankshaftX03 80 -N0101- 03 614NRD Dowel/Pin - Flywheel to CrankshaftX03 80 -N0101- 04 1NRX 85X90A Bearing - Connecting Rod to Crank Shaft 03 90 -N0101- 01 817 XFor Turbo DI, Rod Bearings would be upgraded fromAlSn20Mn (Federal Mogul A-370) to a AlSn10Ni (FederalMogul A-273)X 99A Sensor - CrankshaftX03 99 -N0101- 01 119NRB Encoder Wheel Assembly - Crankshaft SensorX03 99 -N0101- 02 120NRManufacturing process differences between Turbo DIand NA PFI Engines. Encoder design has noassociation with technology upgrade; purely a MCRidea regardless of technology.C Cover - Sensor CrankshaftX03 99 -N0101- 03 1MP-20NRX0401Balancer shafts are not required on Turbo DI due tosmaller engine size. However they are incorporated in theBase NA PFI Engine. In this application, the balanceshafts are integrated into the oil pump.Oil pump integration isn't typical, may need accesscost risk.X 02XX 03Static PartsDrivesMiscellaneousCounter Balance SystemsMoved PartsBoltings: Connecting-Rod BoltsSealing ElementsBearing Elements: Connecting Rod Bearing Shells, Connecting RodFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 2 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XXX 65XX 70XX 75XX 80XX 85XX 90XX 95XX 99X0501A Cylinder Block Assembly - Machined w. Studs, Plugs, etc.05 01 -N0101- 01 11 X X XCost drivers between Turbo DI and NA PFI Engines1. Assume material for Turbo and Base Block are sameand made from Diecast Hypereutectic Aluminum (B390)2. Turbo block smaller overall due to smaller boresize.Using CAE tools, a 11 mm reduction in bore size ontheBase NA PFI (Base Bore 88, Turbo GDI Bore 77), wouldyield a weight savings of approx. 3.5kg. Will confirm withweight measurements on physical parts.3. Added diecast complexity and machining to incorporatefeatures such as inter-bore cooling, Turbo cooling& oilsupply and return lines, piston cooling jets, etc.Industry trend in North America is moving away fromsand cast blocks to diecast block. Initially higherinvestment due to tooling complexity, but over timepays for itself.Need to verify material of block.A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs,etc05 01 -N0101- 02 1Reference Cylinder Block AssemblyA1.1 Cylinder Block Subassembly - Cast05 01 -N0101- 03 1Reference Cylinder Block AssemblyA1.1.1 Cylinder Liners - Cast Iron05 01 -N0101- 04 1XBoth Engines have Cast cylinder liners. Calculatecostdifferential as a result of smaller liners for Turbo DI.Assume Nodular Cast Iron for both Engines, Spec?02Captured below in Bed Plate Assembly03A Bed Plate Assembly - Machined w. Studs, Plugs, etc.05 03 -N0101- 01 12 X XBoth Engines Can operate using either a bedplate,crossbolted mains (rare on in-line engines), ladder caps, andtwo-bolted main bearing caps. The NVH characteristicsdegrade in the same order as above. For a clean sheet I4,bedplate construction would likely be the best option forboth the NA PFI and Turbo DI engines. For cost analysis,will assume both engines have bed plate design andthusonly compare size/weight difference. Material DiecastHypereutectic 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 1Reference Bed Plate AssemblyMiscCylinder BlockCylinder BlocksConnecting ElementsSealing ElementsBearing ElementsBracketsAdaptersPipes, Hoses, DuctingToolsCrankshaft Bearing CapsBedplatesFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 3 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XA1.1 Bed Plate Subassembly - Cast05 03 -N0101- 02 1Reference Bed Plate AssemblyA1.1.1 Bearing - Bolt Through - Insert, Steel 05 03 -N0101- 03 5XAssume same material only, size /weight differenceonly. Need material spec of inserted bearing caps.04A Squirter - Oil, Piston Cooler05 04 -N0101- 01 43 X XRequired for Turbo DIB Bolt - Piston Cooler Valve/Retainer (Check Valve?)05 04 -N0101- 02 44 X XRequired for Turbo DIX 80Boltings & Screws GeneralA Screw - Windage Tray to Bed PlateX05 80 -N0101- 01 45NRB Bolt - Bed Plate to Block, Main (Crank Bearings Approx 3.5")X05 80 -N0101- 02 106Assuming both engines would have Bed Plate design withsame amount of main bear cap thru bolts.Check to see if size and grade are compatible betweentwo engines.C Bolt - Bed Plate to Block (Perimeter Approx. 1.5")X05 80 -N0101- 03 167Assuming both engines would have Bed Plate design willmake assumption same number of perimeter boltsrequired. Any difference would have negligible costimpact.Reasoning larger perimeter on base versus Turbo DI,however greater loading on Turbo DI versus base,thus number of fasteners could potentially beequivalent.D Bolt - Bed Plate to Block ( Perimeter Approx 2.5")X05 80 -N0101- 04 28Assuming both engines would have Bed Plate design willmake assumption same number of perimeter boltsrequired. Any difference would have negligible costimpact.Reasoning larger perimeter on base versus Turbo DI,however greater loading on Turbo DI versus base,thus number of fasteners could potentially beequivalent.E Screw - Sensor, KnockX05 80 -N0101- 05 19NRXDowel Pins/Plugs/Studs - Cylinder BlockA Plugs - Oil GalleyX05 80 -N0101- 10 2NRB Pin/Dowel - Locator Cylinder Block to HeadX05 80 -N0101- 11 2NRC Pin/Dowel - Locator Cylinder Block to BedplateX05 80 -N0101- 12 2NRD Pin/Dowel - Block & Bed Plate (Flywheel Side), AccessoryX05 80 -N0101- 13 2NRDowel Pins/Plugs/Studs - Bed PlateA Plug - Non Turbo Oil Indicator, BedplateX05 80 -N0101- 20 1Clean sheet design could eliminate.B Stud #1 - Accessory, Bed Plate (CC. Cat. Conv. Mnt)X05 80 -N0101- 21 2NRC Stud #2 - Accessory, Bed PlateX05 80 -N0101- 22 2NRX 85A Seal - Crankshaft FrontX05 85 -N0101- 01 110NRB Seal - Crankshaft RearX05 85 -N0101- 02 111NRC Gasket/Seal - Block to Bed Plate (Deposit)X05 85 -N0101- 03 1NR90A Bearing - Crankshaft, Block 1/2 Bearing (Top w. Lub.Pass.) 05 90 -N0101- 01 513For Turbo DI, main bearings would be upgraded fromAlSn20Mn (Federal Mogul A-370) to a AlSn6Si4 (FederalMogul A-590)B Bearing/Shim - Crankshaft Thrust 05 90 -N0101- 02 214Material Upgrade - TBD Talk to Steve on possible material options.C Bearing - Crankshaft, Block 1/2 Bearing (Bottom) 05 90 -N0101- 03 513For Turbo DI, main bearings would be upgraded fromAlSn20Mn (Federal Mogul A-370) to a AlSn6Si4 (FederalMogul A-590)X 99A Windage Tray - Bed PlateX05 99 -N0101- 01 115NRB Sensor - KnockX05 99 -N0101- 02 116NRC Cap - Bed Plate Rear Main BoltsX05 99 -N0101- 04 1MP-16NRBearing Elements: Crankshaft bearing shellsMiscellaneousBoltings/Dowel Pins/Plugs/Studs EtcSealing ElementsPiston CoolingFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 4 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XX0601A Cylinder Head Assembly - Machined w. Studs, Valves,etc.06 01 -N0101- 01 11 X X XCost drivers between Turbo DI and NA PFI Engines1. Assume material for Turbo head A356 T6 versus BaseA319 T7. A356 is required for high temperature strengthand 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 incorporatefeatures 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 1Reference Cylinder Head AssemblyA1.1 Cylinder Head Subassembly - Cast06 01 -N0101- 03 1Reference Cylinder Head Assembly02A Guide - Intake ValveX06 02 -N0101- 01 8MTNRB Guide - Exhaust ValveX06 02 -N0101- 02 8MTNRC Seat - Intake Valve06 02 -N0101- 03 8MTIntake Seats would need to be upgraded - typical upgradewould be from Brico 310 to Como1207.D Seat - Exhaust Valve06 02 -N0101- 04 8MTExhaust seats would need to be upgraded - typicalupgrade would be from MS25Cu to AR20.X 03X06A Cap-Bearing Camshaft, Intake, Phaser TypeX06 06 -N0101- 01 12 X XCost drivers between Turbo DI and NA PFI Engines1. Assume both Base and Turbo are made from samematerial, 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 DifferenceB Cap-Bearing Camshaft, Intake StandardX06 06 -N0101- 02 93 X XCost drivers between Turbo DI and NA PFI Engines1. Assume both Base and Turbo are made from samematerial, either Diecast Aluminum or Power Metal.2. Compare mass difference between both sets of caps.Negligible Weight DifferenceC Cap, Head (Fuel Pump & Vacum Mount)06 06 -N0101- 03 14 XCap unique to Turbo DI, required for HP fuel pump andVacuum pump mounting and driving.Same as aboveX 07Cylinder HeadCylinder Heads - SubsystemCam Shaft Speed SensorGuides for Valve TrainCamshaft Bearing HousingValve Guides. Valve SeatsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 5 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XA Sensor - Cam Shaft, SpeedX06 07 -N0101- 01 15NR20A Cover Assembly- Cylinder Head AssemblyX06 20 -N0101- 01 16A1PCV Subassembly (Built into cover)06 20 -N0101- 02 1Crankcase vent system for DI engine is more difficult andrequires better oil separation. The cost associated withupgraded PCV system is addressed in section 17 below.A2 Cap - Oil FillX06 20 -N0101- 03 1A3 Insert - Fastener, Torque LossX06 20 -N0101- 04 13A4 Insert - Threaded, BrassX06 20 -N0101- 05 380Boltings & Screws GeneralA Bolt - Cap Bearing, Camshaft06 80 -N0101- 01 2374 Extra Required for Extra CapB Bolt & Washer Assembly - Cylinder Head to Block M10X150X06 80 -N0101- 02 108NR: Same QTY, Size and Property Class used in bothEngine Designs.C Bolt & Washer Assembly - Cylinder Head to Block M8x96X06 80 -N0101- 03 29NR - Design choice based on integrating timing cover intoblock and head versus stand alone cover.D Bolt & Washer Assembly - Cylinder Head to Block M8x35X06 80 -N0101- 04 110NR - Design choice based on integrating timing cover intoblock and head versus stand alone cover.E Bolt - Cam SensorX06 80 -N0101- 05 111NRDowel Pins/Plugs/Studs - Cylinder HeadA Bolt - Manifold, Exhaust06 80 -N0101- 10 10Material upgrade on fasteners to stainless steal.B Bolt - Manifold, IntakeX06 80 -N0101- 11 5NRC Pipe Plug -X06 80 -N0101- 12 1NRD Core Plug - Press Fit (Φ18.5 Top)X06 80 -N0101- 13 1NRE Core Plug - Torx (Φ15)X06 80 -N0101- 14 1NRF Cup Plug - Press Fit (Φ40)X06 80 -N0101- 15 1NRG Core Plug - Press Fit (Φ36 Top)X06 80 -N0101- 16 1NRH Core Plug - Ball, AdjusterX06 80 -N0101- 17 1NRI Dowel - Cap, Bearing CamshaftX06 80 -N0101- 18 ??NR85A Gasket - Cylinder Head to Block06 85 -N0101- 01 112 X XBase Engine 2 layer MLS gasket for standard engine.Turbo DI would require 3 layer MLS gasket.B Seal - Cover to Cylinder Head, PerimeterX06 85 -N0101- 02 113NRC Seal - Cover to Cylinder Head, InnerX06 85 -N0101- 03 114NR0701A Valve - Intake07 01 -N0101- 01 81 X XIntake valves would need to be upgraded - typicalupgrade would be from nitrided JIS SUH11 (Fe-1.5Si,8.5Cr, 0.5C) to SilichromeCylinder Head CoversBoltings: Cylinder Head, Cylinder Head Cover, ManifoldSealing Elements: Cylinder Head, Cylinder Head Cover, ....Inlet ValvesValve TrainsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 6 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?X02A Valve - Exhaust07 02 -N0101- 01 82 X XExhaust valves would need to be upgraded - typicalupgrade would be from nitrided JIS SUH 35 (Fe, 9Mn,21Cr 4Ni, 0.5C and 0.4N) to Inconel head and Silichromestem. Exhaust valves on Mini Cooper Turbo DI areSodium filled as well. This design approach is notconsidered preferred and thus will note be includedin costanalysis.X 03A Spring - ValveX07 03 -N0101- 01 163NRX 04A Seat - Spring UpperX07 04 -N0101- 01 164NRB Retainer - Valve SpringX07 04 -N0101- 02 325NRCSeal-Seat Subassembly - Spring Lower (Seat, Seal and Coil Spring)X07 04 -N0101- 03 166NRX 05A Adjuster - Hydraulic,X07 05 -N0101- 01 167NRB Follower- Roller FingerX07 05 -N0101- 02 168NR06A Camshaft Assembly - Intake Machined07 06 -N0101- 01 19 X X1. Length of Camshaft reduced, mass reduction.2.Feature required to drive high pressure fuel pumpfor DI.3. Material Assumption, both Base and Turbo DI madefrom Nodular Cast Iron, ChilledA1 Camshaft - Intake Machined07 06 -N0101- 02 1Reference Camshaft Assembly-IntakeA2 Encoder Wheel - IntakeX07 06 -N0101- 03 1NRB Camshaft Assembly - Exhaust Machined07 06 -N0101- 10 110 X X1. Length of Camshaft reduced, mass reduction.2.Feature required to drive high pressure fuel pumpfor DI.3. Material Assumption, both Base and Turbo DI madefrom Nodular Cast Iron, ChilledB1 Camshaft - Exhaust Machine07 06 -N0101- 11 1Reference Camshaft Assembly-ExhaustB2 Encoder Wheel - ExhaustX07 06 -N0101- 12 1NRx 08A Cam Phaser Assembly- IntakeX07 08 -N0101- 01 111Assumption Base and New Technology Packages haveDual VVT.Outlet ValvesValve SpringsSpring Retainers, Cotters, Spring SeatsValve Actuation Elements: Rockers, Finger Followers, HydraulicLash Adjusters,...CamshaftsCamshaft Phaser and/or Cam SprocketsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 7 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XBX07 08 -N0101- 20 112NR - Assumption Base and New Technology Packageshave Dual VVT. Thus exhaust sprocket is replaced withcam phaser assembly.X 80A Bolt - Cam Phaser, Camshaft, IntakeX07 80 -N0101- 01 113NRB Bolt - Sprocket, Camshaft, ExhaustX07 80 -N0101- 02 114NRX 15X 16E Bolt-Flange -Control Valve Oil To Cylinder HeadX07 80 -N0101- 20 117NRX 99A Control Valve - Oil, Intake VVTX07 99 -N0101- 01 118NRBX07 99 -N0101- 02 1NRXX0801A Sprocket - Crankshaft, Timing Drive08 01 -N0101- 01 11 X XSmart sprocket required to help counter act cyclicloadingeffects from Vacuum Pump and High Pressure Pump.Cost impact approx. $1-$2/Engine. Note, cost impactis associated with royalty fee; no manufacturing costimpact.B Sprocket - Crankshaft, Oil Pump DriveX08 01 -N0101- 02 12Surrogate DesignX 02A Tensioner - Camshaft TimingX08 02 -N0101- 01 13NRX 03A Tensioner Arm Assembly - Timing Chain, LowerX08 03 -N0101- 01 14NRA1 Tensioner Arm - RHSA2 Tensioner Arm - LHSB Guide Assembly - Timing Chain, Upper Cam to CamX08 03 -N0101- 10 15NRB1 Bracket - MountingB2 Guide Rail -UpperX05A Chain Assembly - TimingX08 05 -N0101- 01 16 X XMay require heavier chain to handle additional timing driveload created by the vacuum pump and high pressure fuelpump.Turbo DI has Roller Chain and NA PFI Engine hasInverted Tool/Silent Chain? Verify and determine ifthere is cost impact. Perhaps MCR on Base?X06XX 65A Nose - Crankshaft, Timing Sprocket & Accessory PulleyX08 65 -N0101- 01 17NRX 80Sprocket - Cam, Exhaust (Replaced with Exhaust CamPhaser forAnalysis)Control Valve - Oil, Exhaust VVT ( Added into assumption for costanalysis)BoltingsMiscellaneousTiming DrivesTiming Wheels (Sprockets)TensionersGuidesBelts, ChainsCoversAdaptorsBoltingsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 8 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XA Bolt - Crankshaft NoseX08 80 -N0101- 01 18NRB Washer - Crankshaft NoseX08 80 -N0101- 02 19NRC Bolt - Guide, Timing Chain Upper to cylinder head.X08 80 -N0101- 03 110NRD Bolt - Tension Arm Subassembly to BlockX08 80 -N0101- 04 311NRXX09X01A Pulley/Damper Assembly - CrankshaftX09 01 -N0101- 01 11 X XNR - Turbo DI has single mode damper similar to BaseNA PFI EngineDual mode dampers (DMD) reduce vibration in twodirections. DMD's are typical for Turbo DI Engines.DMDs contain two separate dampers, one is fortorsional crankshaft vibration (twisting) and the other isfor bending vibration (bending up and down).B Wheel - Drive, Coolant Pump (Friction Driven)X09 01 -N0101- 02 12NRIf mechanical water pump + small auxiliary Turbopump was replaced with single larger electricwater , this item would be removed and costsavings put towards electric pump.C Actuating Drive Assembly - Drive Pulley & Water PumpX09 01 -N0101- 03 13NRIf mechanical water pump + small auxiliary Turbopump was replaced with single larger electricwater , this item would be removed and costsavings put towards electric pump.X 02A Tensioner Assembly - Accessory DriveX09 02 -N0101- 01 14NRX 03XX05A Belt - Accessory DriveX09 05 -N0101- 01 15NRX 65XX 70XX 75XX 80A Bolts - Pulley CrankshaftX09 80 -N0101- 01 36NRB Bolts - Drive Gear/Wheel Coolant PumpX09 80 -N0101- 02 37NRIf mechanical water pump + small auxiliary Turbopump was replaced with single larger electricwater , this item would be removed and costsavings put towards electric pump.C Bolt - Tensioner Assembly (Secures to Alternator)X09 80 -N0101- 03 18NRD Bolt - Actuating Drive Assembly - Drive Pulley & Water PumpX09 80 -N0101- 04 39NRIf mechanical water pump + small auxiliary Turbopump was replaced with single larger electricwater , this item would be removed and costsavings put towards electric pump.Accessory DrivesPulleysTensionersGuidesBoltingBeltsAdaptorsPipes, Hoses, DuctingBracketsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 9 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?X1001A Manifold Assembly - Intake10 01 -N0101- 01 11 X X XAssumptions: Intake manifold of Turbo DI is approximatelyhalf size of NA PFI Engine. Also base engine has intaketumbler to improve fuel atomization which helps meet coldstart and idling targets. Although FEV feels additionaltumbler device may be avoided with proper intake manifolddesign and head design.Long runner intake manifolds are required in NAengines for tuning pressure wave. Want to make surepeak pressure hits at intake valve.X 02A Air Filter Box AssemblyX10 02 -N0101- 01 12NRX 03A Air FilterX10 03 -N0101- 01 13NRX 05A Throttle Body Assembly - Electronically ControlledX10 05 -N0101- 01 14NRX 65XX 70A Tube - Elbow, Air Intake to Filter BoxX10 70 -N0101- 01 15NRB Tube - Flex, Air Intake to ElbowX10 70 -N0101- 02 16NRC Coupler - Tube Flex to Vehicle MountX10 70 -N0101- 03 17NRD Tube - Air Filter Box via MFS to Turbo InletX10 70 -N0101- 04 18NR - This would go direct to ETB on Base EngineX 75A Bracket - Support, Intake ManifoldX10 75 -N0101- 01 19NRX 80A Nut - Intake Manifold Assembly to Cylinder HeadX10 80 -N0101- 01 510NRB Nut- Bracket, Intake Manifold SupportX10 80 -N0101- 02 211NRC Bolt- Bracket, Intake Manifold SupportX10 80 -N0101- 03 112NRD Bolt- Throttle Body to Intake ManifoldX10 80 -N0101- 04 313NRE Bolt - Manifold Absolute PressureX10 80 -N0101- 05 114NRF Grommet - Air Filter Box to Intake Manifold MountingX10 80 -N0101- 06 315NRG Bolt - Air Filter Box To Intake ManifoldX10 80 -N0101- 07 116NRH Duplicate Part to "F"X 17I Insert - Air Filter - Intake Torque Loss PreventionX10 80 -N0101- 09 118NRJ Clamp - Tube, Mass Air Flow OutletX10 80 -N0101- 10 119NRK Clamp - Tube, Turbo InletX10 80 -N0101- 11 120NR - This would clamp would be used to secure inlettubedirectly to ETB( Move to PCV)LRetainer - Turbo Intake Pipe to PCV SubassemblyX1080-N0101-12121X 85A Gasket-Intake Manifold, Main Flange to Cylinder HeadX10 85 -N0101- 01 122NRIntake ManifoldsAir Filter BoxAir FiltersThrottle Housing Assembly; including SuppliesAdapters: Flanges for Port Shut-offPipes, Hoses, DuctingBracketsIntake SystemsBolting & ClampsSealing ElementsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 10 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XB Gasket-Electronic Throttle Body to Intake ManifoldX10 85 -N0101- 02 423NRC Gasket - Mass Flow Sensor (MFS) - Air Filter BoxX10 85 -N0101- 03 124NRX 99A Sensor - Mass Flow Meter, Hot WireX10 99 -N0101- 01 125NRB Sensor - Manifold Absolute Pressure (MAP)X10 99 -N0101- 02 126NR1101A Fuel Rail w. High Pressure Sensor Assembly11 01 -N0101- 01 1A1 Fuel Rail - High Pressure11 01 -N0101- 02 1MP-1 X X XAs a result of higher fuel pressures (approx. 1200psi), thefollowing 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 Pressure11 01 -N0101- 03 1MP-1 X1 . Require pressure senor on fuel rail for DI; not requiredfor PFI engine.04A Fuel Injector Assembly - Solenoid, 7 Hole11 04 -N0101- 01 42 X X X X1. Replaces Low Pressure Port Injectors07A Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off Intake Cam)11 07 -N0101- 01 13 X1, Required for DI system, not required PFI system.Look at cost Delta for Rotary pump which is drivenoffback of intake Cam versus Cam Lobe driven pump.Rotary pump assembly more expensive. However,need to consider entire subsystem which includeshead changes [additional cast material (Approx. 1kg) and added precision machining (Especially tappetbore and flange face) ], cam changes ( Additionallobe on intake cam), and a few others.70A Pipe Assembly - Fuel, High Pressure, Pump to Rail11 70 -N0101- 01 14 X1. Connects High Pressure Pump to Fuel Rail on DIEngine; not required for PFI system.B Tube & Hose Fuel LP & Purge AssemblyX11 70 -N0101- 02 1MP-4NRB1 Hose - Fuel Feed, Low PressureX11 70 -N0101- 03 1MP-4NRB2 Hose - Fuel, PurgeX11 70 -N0101- 04 1MP-4NRB3 Retainer - Fuel Hoses to Bracket, LP & PurgeX11 70 -N0101- 05 1MP-4NRB4 Retainer- Fuel Hose, LP & PurgeX11 70 -N0101- 06 1MP-4NRXX 75D Bracket Assembly - Tube, Fuel Low Pressure and PurgeX11 75 -N0101- 01 1MP-4NR80A Bolt - Fuel Rail11 80 -N0101- 01 45 X XDI has increased fastener quantity and size for securingfuel rail.B Bolt - Fuel Pump11 80 -N0101- 02 36 XAdded for DIC Retainer - Fuel Injector11 80 -N0101- 03 47 XAdded for DID Washer, Retainer - Fuel Injector11 80 -N0101- 04 48 XAdded for DIE O-ring Retainer, Fuel Injector11 80 -N0101- 05 49 XAdded for DIF Spacer - Retainer, Fuel Injector11 80 -N0101- 06 410 XAdded for DIFuel Induction SystemsFuel Injection PumpsFuel InjectorsBracketsPipes, Hoses: Low Pressure, High PressureBoltingMiscellaneousFuel RailsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 11 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?X85A Seal - High Pressure Fuel Pump to Cylinder Head11 85 -N0101- 01 111 XAdded for DI1201A Manifold - Exhaust, Dual Wall12 01 -N0101- 01 11 XMaterial upgrade required to a stainless steel capable ofoperating @ 1050C. Recommendation DIN 14826Stainless Material.Fabricated dual wall manifolds may offer a 30% costreduction over the cast manifold but these designsare package specific and require a significant amountof engineering development.Nodular Cast IronX 04XX 05AClose Couple Catalytic Converter Subass'y- 3 Way (Exhaust Pipe Ass'Y)X12 05 -N0101- 01 1NR - Estimate close coupled catalytic convertersubsystem for Turbo DI technology and NA PFI engineapproximately equivalent in cost for this study based onsimilar power flows.Consider higher temperatures and quicker light-offwith direct injection offset by heat sink from turboassembly hardware.BUnderbody Catalytic Converter Subass'y - ? Way (Under Body Ass'y)X12 05 -N0101- 02 1NRX 07A Resonator Subassembly (Under Body Ass'y)X12 07 -N0101- 01 1NRB Muffler & Tail Pipe Subassembly (Under Body Ass'y)X12 07 -N0101- 02 1NRX 08A Sensor Assembly - Oxygen/Lambda Before CatalystX12 08 -N0101- 01 12NRB Sensor Assembly - Oxygen/Lambda After CatalystX12 08 -N0101- 02 13NRX 65AFlex Pipe Subass'y - Under Body Exhaust Ass'y to Exhaust Pipe Ass'yX12 65 -N0101- 01 14NRX 70A Exhaust Pipe AssemblyX12 70 -N0101- 01 15NRB Underbody Exhaust Pipe AssemblyX12 70 -N0101- 02 16NR75A Bracket Subassembly - Exhaust Manifold w. IntegratedGasket 12 75 -N0101- 01 17 X X1. 3 layer sealing Turbo, 2 layer base NA PFIB Bracket Subassembly- Heat Shield, Top, Turbo12 75 -N0101- 02 18 XRequired to cover Turbo AssemblyC Bracket Subassembly - Heat Shield, Exhaust Outlet toBlockX12 75 -N0101- 03 19NRAs Turbo DI becomes more main stream,prediction is that heat shields will not only be usedfor heat control, but also be required to dampenand absorb combustion noise. Investigate costimpact for composite type structures.XD Bracket Subassembly - Exhaust Lower - CC. Cat. Conv.X12 75 -N0101- 05 1MP-9NRAs Turbo DI becomes more main stream,prediction is that heat shields will not only be usedfor heat control, but also be required to dampenand absorb combustion noise. Investigate costimpact for composite type structures.XExhaust SystemsOxygen SensorsAdaptersPipes, Hoses: Low Pressure, High PressureSealing ElementsExhaust ManifoldCollector PipesCatalystsSilencers (Mufflers)BracketsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 12 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XE Strap - Manifold Mount Face (Torque Loss)X12 75 -N0101- 06 1MP-10NR - Components not industry standard for Base or TurboDIF Strap - Manifold Mount Face ( Torque Loss)X12 75 -N0101- 07 1MP-10NR - Components not industry standard for Base or TurboDIG Strap - Manifold Mount Face (Toque Loss)X12 75 -N0101- 08 1MP-10NR - Components not industry standard for Base or TurboDIH Bracket Subassembly #1 - C.C. Catalytic Con. To Bed PlateX12 75 -N0101- 09 1MP-10NRI Bracket Subassembly #2 - C.C. Catalytic Con. To Bed PlateX12 75 -N0101- 10 1MP-10NRJ Bracket Subassembly - O2 Sensor (Before CC Cat. Conv.)X12 75 -N0101- 11 1MP-10NRK Fixturing Hardware General - Exhaust Underbody AssemblyX12 75 -N0101- NANR80A Nut- Manifold Exhaust to Cylinder Head 12 80 -N0101- 01 1011 X XMaterial upgrade to stainless to handle higher exhausttemperaturesB Bolt - BRKT Heat Shield Turbo to Exhaust ManifoldBRKTX12 80 -N0101- 02 1212NR - Similar fasteners exist for both designsD Nut - BRKT Heat Shield Exhaust to Exhaust ManifoldBRKTX12 80 -N0101- 04 114NR - Similar fasteners exist for both designsE Nut - C.C. Catalytic Converter to Bed Plate (CopperNut)X12 80 -N0101- 05 2MP-14NRF Nut - Turbo to C.C. Catalytic Converter 12 80 -N0101- 06 3MP-14XAdd for Turbo, Stainless Material?G Nut - Exhaust Manifold to Turbo12 80 -N0101- 07 4MP-14X XIf there was no Turbo, assume same four nuts wouldberequired to mount directly between manifold and exhaustpipe or Catalytic Converter Subassembly. However inTurbo DI case need to cover cost impact of StainlessSteel Nuts Versus Standard.H Nut - Bracket, C.C. Catalytic Converter to Bed PlateX12 80 -N0101- 08 2MP-14NRI Clamp Assembly - CC Catalytic Converter to Exhaust PipeX12 80 -N0101- 09 1MP-14NRJ Fastening Hardware General - Exhaust Underbody AssemblyX12 80 -N0101- TBDX85A Gasket - Turbo Inlet to Exhaust Manifold 12 85 -N0101- 01 115 XRequired with TurboB Gasket - Turbo Outlet to Catalytic ConverterX12 85 -N0101- 02 1MP-15If there was no Turbo, assume gasket would be usedtomount directly between manifold and exhaust pipe orCatalytic Converter Subassembly.13X 01A Pan -OilX13 01 -N0101- 01 11NR02A Oil Pump Assembly13 02 -N0101- 01 12 XPiston Cooling Jets, Turbo Charge lubrication andExternal Oil cooler will require increased oil capacity. Willneed 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 pushesmore oil through the pump at the same rpm than astock pump.06Sealing ElementsBoltingOil Pans (Oil Sump)Lubrication Systems, Oil Pans/SumpsOil FilterOil PumpsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 13 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XA Filter Cooler Assembly - Oil (Includes Seals)13 06 -N0101- 01 13 XRequire oil cooler in circuit to help cool oil going into Turboassembly.70A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger13 70 -N0101- 01 14 XRequired with TurboB Tube Assembly - Oil, Turbo to Engine Block (Piston Squirter's)13 70 -N0101- 02 15 XRequired with Turbo80A Screw - Oil Pan to Bed PlateX13 80 -N0101- 01 166NRB Bolt - Oil Pump AssemblyX13 80 -N0101- 02 37NRC13 80 -N0101- 03 48 XRequired with TurboD Bolt - Tube Assembly , Oil, Turbo Inlet13 80 -N0101- 09 19 XRequired with TurboE Clamp - Tube Assembly, Oil, Cooler/Filter Outlet13 80 -N0101- 05 110 XRequired with TurboF Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet13 80 -N0101- 06 211 XRequired with TurboG Screw - Tube assembly Oil level IndicatorX13 80 -N0101- 07 112NR85A Gasket - Oil Pan (Deposit)X13 85 -N0101- 01 1NRB Plug & Gasket Subassembly - Oil Pan, DrainX13 85 -N0101- 02 1NRC Seal - Tube Assembly, Oil, Turbo Inlet13 85 -N0101- 03 115 XRequired for TurboD Compression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet13 85 -N0101- 04 416 XRequired for Turbo99A Chain - Crank Shaft to Oil PumpX13 99 -N0101- 01 117NRXB Tube Assembly - Oil Level IndicatorX13 99 -N0101- 02 118NRC Sensor - Oil PressureX13 99 -N0101- 03 119NRD Cover - Oil Pump ChainX13 99 -N0101- 06 1MPNRE Sensor - Oil TemperatureX13 99 -N0101- 04 120NRF Oil - Synthetic13 99 -N0101- 08 1X XSynthetic oil required for turbocharged applications. Needto consider cost of initial factory fill.1401A Pump Assembly - Coolant (Primary Mechanical)X14 01 -N0101- 01 11NRUpgrade system from mechanical pump + smallerauxiliary to single larger electric water pump forreduced parasitic losses and I improved frictioncharacteristics. Need to investigate cost impact(Conventional Water Pump $25.50) . Need toconsider other H/W which can be removed ifsingle electric water pump is utilized.B Pump- Auxiliary Coolant, Electric14 01 -N0101- 02 12 XRequired for Turbo Cooling following engine shut down.X 02A Thermostat/Coolant Flow Valve Assembly -CoolantX14 02 -N0101- 01 13NR - Today having Integrated Electric Thermostat onTurbo DI and a conventional mechanical thermostat on theNA PFI is more typical. However I industry trend ismoving towards electric thermostats for both technologylevels. Thus assumption is same technology would existin both applications.Water PumpsBoltings & ClampsSealing Elements: Oil Pan Gasket,...Bolt - Filter Cooler AssemblyPipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,Low Pressure.MiscellaneousThermostat HousingCooling SystemsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 14 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XSensor - Thermostat (Integrated into Housing?)X14 02 -N0101- 02 1Same as aboveSensor - Engine Temperature (Includes O-ring and Clip)X14 02 -N0101- 03 14NR70A Tube - Mech. Pump to Thermostat/Coolant Valve Ass'yX14 70 -N0101- 01 15NRB Hose Assembly - Turbo Assembly to Thermostat/CoolantValve14 70 -N0101- 02 16 XRequired for Turbo CoolingC Hose Assembly - Auxiliary Pump to Turbo14 70 -N0101- 03 17 XRequired for Turbo CoolingD Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary Pump14 70 -N0101- 04 18 XRequired for Turbo CoolingE Hose - Radiator to Thermostat/Coolant Valve AssemblyX14 70 -N0101- 05 1NRF Hose - Thermostat/Coolant Valve Assembly to RadiatorX14 70 -N0101- 06 1NRG Hose - Heater Core to Thermostat/Coolant Valve AssemblyX14 70 -N0101- 07 1NRH Hose - Thermostat/Coolant Valve Assembly to HeaterCoreX14 70 -N0101- 08 1NR75A Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y14 75 -N0101- 01 1MP XRequired to secure auxiliary electric pump for coolingturbo.80A Bolt - Water Pump, MechanicalX14 80 -N0101- 01 513NRB Bolt - Thermostat/Coolant Flow Valve AssemblyX14 80 -N0101- 02 314NRC Retainer(s) - Tube, Mech Pump to Thermostat Valve Ass'yX14 80 -N0101- 03 ??15NRD Clamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ Thermo14 80 -N0101- 04 116 XRequired for Turbo CoolingE Bolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKTMount14 80 -N0101- 05 1XRequired for Turbo CoolingF Bolt-Hose, Inlet and Outlet @ Turbo14 80 -N0101- 06 218 XRequired for Turbo CoolingG Bolt - Auxiliary Pump to Oil Filter Cooler Bracket Assembly14 80 -N0101- 07 219 XRequired for Turbo CoolingI Clamp - Hose, Auxiliary Pump to Turbo14 80 -N0101- 09 121 XRequired for Turbo CoolingJ Clamp - Hose, Oil Filter Cooler Assembly to Auxiliary Pump14 80 -N0101- 10 222 XRequired for Turbo CoolingK Clamp - Inlet and Outlet Radiator HosesX14 80 -N0101- 11 4NRL Clamp - Inlet and Outlet Heater Core HosesX14 80 -N0101- 12 4NRM Washer Banjo Bolt - Hose Coolant Inlet & Outlet Turbo14 80 -N0101- 13 4MP-24 XRequired for Turbo CoolingX 85A Seal - Water Pump MechanicalX14 85 -N0101- 01 125NRB Seal - Thermostat/Coolant Flow Valve AssemblyX14 85 -N0101- 02 126NR1501A Turbo Charger Assembly15 01 -N0101- 01 11 XRequire for Turbo SystemTwin Scroll turbocharger capable of operating at 1050CEGT (Exhaust Gas Temperature) is currently the bestoption for transient operation.Future cost reduction may include fabricated exhaustmanifold scrolls integrated with the exhaust manifold.Future technology advances may include avariable geometry turbo, but there are non inexistence today capable of operating above 950CEGT.A1 Waste Gate Anti Surge Control Valve15 01 -N0101- 02 1XSame as above05Turbo Chargers (Assemblies)Heat ExchangerInduction Air Charging SystemsPipes, Hoses, DuctingBracketsBoltings & ClampsSealing ElementsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 15 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XA Cooler Assembly - Charged Air15 05 -N0101- 01 12 XCharged air cooler required for Turbo SystemEstimated unit cost savings to move fromconventional air to air charge air cooler to watertoair charge air cooling subsystem. Note that thetooling bill is higher but the A-ACAC toolingneeds to be completely duplicated for a newvehicle application whereas the W-ACAC is onlypartially duplicated. Improved performance forstop and go city driving.6570A Tube Assembly - Turbo Waste Gate Pneumatic Control15 70 -N0101- 03 13 XRequired for Turbo SystemB Tube Ass'y w. Vehicle Tie Down Resonator, Air CoolerInlet 15 70 -N0101- 19 1BI Tube - Turbo Outlet to Vehicle Mount Coupler15 70 -N0101- 20 14 XPart of air charge air cooling & delivery subsystemB2 Coupler - Turbo Outlet Tube to Cooler Intake Tube15 70 -N0101- 21 15 XPart of air charge air cooling & delivery subsystemB3 Tube - Coupler to Charge Air Cooler15 70 -N0101- 22 16 XPart of air charge air cooling & delivery subsystemC Tube Ass'y w. Vehicle Tie Down, Air Cooler OutletXPart of air charge air cooling & delivery subsystemC1 Tube - Charge Air Cooler Outlet15 70 -N0101- 01 17 XPart of air charge air cooling & delivery subsystemC2 Tube - Formed, Charge Air Cooler Tube Outlet15 70 -N0101- 31 18 XPart of air charge air cooling & delivery subsystemD Tube - Elbow, Upper to Charged Air Coupler By-Pass15 70 -N0101- 40 19 XPart of air charge air cooling & delivery subsystemE Tube - Coupler Y Branch to By-Pass15 70 -N0101- 41 110 XPart of air charge air cooling & delivery subsystemF Tube - Elbow Coupler By-Pass to Throttle Body15 70 -N0101- 42 111 XPart of air charge air cooling & delivery subsystemG Tube - Charged Air Bypass to Silencer15 70 -N0101- 43 112 XPart of air charge air cooling & delivery subsystemH Tube - Flex Elbow, Silencer to Environment15 70 -N0101- 44 113 XPart of air charge air cooling & delivery subsystem75A Bracket - Support, Turbo Assembly15 75 -N0101- 01 114 XRequired to support mass of Turbo assembly hangingoffExhaust Manifold.80ABolt - Turbo Assembly to Exhaust Manifold (Moved-12)15 80 -N0101-BBolt - Turbo Assembly to Exhaust Pipe (Moved-12)15 80 -N0101-C Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 03 117 XRequired to support Turbo AssemblyD Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 04 118 XRequired to support Turbo AssemblyE Bolt - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 05 219 XRequired for Turbo Assembly SubsystemF Nut - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 06 120 XRequired for Turbo Assembly SubsystemH Clamp - Tube, Large, Turbo to Throttle Body15 80 -N0101- 08 922 XPart of air charge air cooling & delivery subsystem. Noteone clamp is accounted for in intake subsystem whichwould connect intake tube directly to ETB in basesystems.I Bolt - Tube, Charge Air Cooler to Vehicle15 80 -N0101- 09 2XPart of air charge air cooling & delivery subsystemJ Screw - Sensor, Charge Air Temperature15 80 -N0101- 10 124 XPart of air charge air cooling & delivery subsystemL Clamp - Tubing Charged Air By-Pass15 80 -N0101- 12 326 XPart of air charge air cooling & delivery subsystemM Retainer - Vehicle, Charged Air By-Pass Elbow15 80 -N0101- 13 1XPart of air charge air cooling & delivery subsystem99A Vacuum Reservoir - Turbo Waste Gate15 99 -N0101- 01 129 XRequired for Turbo Assembly SubsystemB Value - Thrust Control, Turbo Waste Gate PneumaticControl15 99 -N0101- 02 130 XRequired for Turbo Assembly SubsystemAdaptersPipes, Hoses, DuctingMiscellaneousBracketsBoltings, Clamps, Misc FasteningFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 16 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XC Sensor - Intake Temperature, Outlet Charged Air Cooler15 99 -N0101- 03 131 XPart of air charge air cooling & delivery subsystemD Baffle - Charge Air By-Pass15 99 -N0101- 04 132 XPart of air charge air cooling & delivery subsystem1702A PCV ASSEMBLY - (Built into Cylinder Head Cover)X X• The crankcase vent system for a DI engine is moredifficult and requires better oil separation. Thismay drivesome additional cost into the system if a good result cannot be engineered from a separator internal to thecamcover.A1 Valve - Non Return Intake Hose Side17 02 -N0101- 01 1Evaluate upon teardown of PCV Subsystem1A2 Separator - Cyclone17 02 -N0101- 10 1Evaluate upon teardown of PCV SubsystemA3 Valve - Pressure Control17 02 -N0101- 20 1Evaluate upon teardown of PCV SubsystemA4 Valve - Oil Drain17 02 -N0101- 30 1Evaluate upon teardown of PCV SubsystemA5 Valve - Non Return Intake Manifold Side17 02 -N0101- 40 1Evaluate upon teardown of PCV SubsystemX 70A Hose Assembly- PCV H/W to Intake ManifoldX17 70 -N0101- 01 16NRB Hose Assembly- Air Intake to PCV H/W (With Valve orSensor??)X17 70 -N0101- 02 1MP-6NRX 75XX 80XX 85XX 90XX 95XX 99A Retainer - Hose Assembly - Air Intake to PCV H/WX17 99 -N0101- 01 16NR60X 01A Spark PlugX60 01 -N0101- 01 41NR02A Power Train Control Module (PCM) Assembly - Hardware 60 02 -N0101- 01X XThe PCM H/W is carry over except for the PFI drivers.GDI drivers use a 75-80VDC Boost Circuit and 25APeak/Hold Drivers.The turbo is just another low-side driver really nocost.Estimated cost from Tech Team on GDI PCM maycost $40-45 more than a PFI PCM.B Power Train Control Module (PCM) Assembly - Software60 02 -N0101- 50X X• Control system is much more complicated in ordertocontrol injection timing, split injections, fuel rail pressure,electric water pump, electric thermostat, etc.Costs covered by Indirect Cost Multiplier03Sealing ElementsBearing ElementsToolsMiscellaneousEngine Management Systems, Engine Electronic Systems,Electrical SystemsPipes, Hoses, DuctingBracketsBoltingsOil/Air SeparatorEngine Electrical Systems (including Wiring Harnesses, EarthStraps, Ignition Harness, Coils, Sockets)Spark Plugs, Glow PlugsEngine Management Systems, Engine Electronic SystemsBreather SystemsFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 17 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411APPENDIX C.1 Comparison Bill of Materials Excerpt - Case Study #0101,2007 Mini Cooper 1.6L I4, Turbo, Direct InjectionAPPENDIX C.1,Printed:12/8/2009Powertrain Description:2007 Mini Cooper, 1.6L I4, 16V DOHC, DI, Turbo, iVVT, 173hpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )



# ITEM ASY LVLQTY/P.T. 

# Label #BRIEF EXPLANATION OF DIFFERENCESNotes: Addititional Items RequiringInvestigation.Design modifications for MaterialCost Reductions (MCR's).Additional Technology Advancesor Performance Upgrades<NR>= Item cost impact assumedunaffected or negligibly affected bytechnology differencesCHECK OFF ATTRIBUTESWHICH ARE DIFFERENTBETWEEN COMPARISONTECHNOLOGY PACKAGES



# Part ExistencePART NUMBERNAME/DECRIPTION

SUBSYSTEM SUB-SUBSYSTEM 

# Material/Finish(s) Weight/ Size Function Performance QTY/P.T. Royalty

ASSEMBLY SUBASSEMBLY COMPONENTDefault, indicates cost study required for identified item.Indicates cost analysis potentially required, additional detailsrequired.Indicates common item/cost factor found in both baseline and newtechnology package, no cost analysis required.Same as above, however with potential MCR or TechnologyAdvance ConsiderationsGENERAL PARTINFORMATIONX?XA Ignition Coil Assembly - Single Spark60 03 -N0101- 01 42 XRequire upgrade in ignition coils, Turbo typically75-100mJ, Base NAPFI 40-45mJ.Need to order ignition coil assemblyB Battery AssemblyX60 03 -N0101- 20 1NRC Wire Harness Assembly #1 - Engine, Main60 03 -N0101- 30 13 X X XAdded wiring complexity due to more sensors andactuators.X 80A Cover - COP harnessX60 80 -N0101- 01 1MPNR70X 01A Starter Motor AssemblyX70 01 -N0101- 01 11NRX 02A Alternator AssemblyX70 02 -N0101- 01 12NRX 03A Power Steering Pump Assembly -ElectronicX70 03 -N0101- 01 13NRIn future the electric steering pump will become moreof a standard on both Turbo DI as well as Base.Should include in second case cost model.04A Vacuum Pump Assembly70 04 -N0101- 01 14 XOn Turbo DI Vacuum pump required for brakes andaccessories.X 05A Air Conditioning Compressor AssemblyX70 05 -N0101- 01 15NRX 70A Hose - Vacuum Pump, Brake BoosterX70 70 -N0101- 01 16NRX 75A Bracket - AC Compressor MountX70 75 -N0101- 01 17NRB Bracket - Retention tube and wire harnessX70 75 -N0101- 03 1MPNR80A Bolt - Vacuum Pump70 80 -N0101- 01 28 XRequired to mount vacuum pump to head.B Bolt - Starter Motor Assembly to BlockX70 80 -N0101- 02 39NRD Bolt - Alternator Assembly to BlockX70 80 -N0101- 03 310NRE Bolt - AC Comp. Mounting Bracket to Block & Bed PlateX70 80 -N0101- 04 411NRF Bolt - AC Compressor Assembly to Mounting BracketX70 80 -N0101- 05 312NRG Fastener - Steering Pump Assembly to VehicleX70 80 -N0101- 06 ??13NRBoltingsPipes, Hoses, DuctingBracketsGeneratorsPower Steering PumpsVacuum PumpsAir Conditioning CompressorsBoltingsAccessories (Starter Engines, Generators, Power SteeringPumps, etc)Starter EnginesFile:Appendix C.1 Final Report 120809.xlsEPA Contract: EP-C-07-069 WA1-3C.1, Page 18 of 18Author: Greg Kolwich(248) 373-6000 Ext.2411

# 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® Mapp ing 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 attach ed to other parts or

products which have components inside them, i.e. bo lts with captured washers,

welded brackets, insert molded parts, purchased ass emblies.

Pre-processed Part : Are parts that have undergone additional processe s before

they can be used, i.e. Anodizing, powder coat, or p aint. 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 shoul d 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 l ike 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 par t, and then fasten the part.

Operation : Operations such as moving the product, operator m ovement, or

changes to the direction of insertion, part manipul ation, 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, a nytime material is removed, as in

machining operations such as milling, boring, punch ing, drilling, etc.

Inspect: Represents inspection steps in an assembly. Inspe ctions are non-value

added processes that should be eliminated or automa ted.

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 co unt. Includes oil,

grease, coolant, and glue.APPENDIX E.1 Material Costing Database ExcerptAppendix E.1Printed:12/9/2009Active Rate2008A. CARBON & ALLOY STEELS (SAE1000-9000 SERIES)A1. CARBON STEELA1.110XXPlain Carbon SteelMn 1.00% MaxLow Carbon Steel SAE J403 1008/1010 Coil Brackets, Spacers LC-Steel-1000S, Coil 0.45$ AMM Reference, MEPS, USGSMedium Carbon Steel SAE J403 1018 Coil Splash Pans, Dampers, Windage TrayMC-Steel-1000S, Coil0.55$ Online Metals, Metals Depot, Speedy Metals, All Metals,Industrial Metal Sales w/ AMM spot checkLow Carbon, Hot Dip GalvanizedSteed.SAE J403 1008/1010 Coil PCV BafflesLC-GSteel-1000S, Coil0.48$ Premium SteelMedium Carbon Steel SAE J403 1018 BarMC-Steel-1018, Bar0.74$ Metals Express, Industrial Metal, Online Metals, Metals DepotHigh Carbon Steel SAE J403 1040 Bar (1-3")HC-Steel-1040S, Bar 0.80$ Online Metals, Speedy Metals,All MetalsA1.312XXResulfurized and Rephosphorized12L14 Leaded Bar Bar Bushings, Inserts, Couplings LC-Steel-1214, Bar 0.62$ Online Metals, Speedy Metals,All Metals1215 Replacement to 12L14 Bar Bushings, Inserts, Couplings LC-Steel-1215, Bar 0.62$ Purchasing MagazineLow Carbon Steel Tubing 1215Tube Metal Tubing coolant lines, oil lines, etc. LC-Steel-1215, Tubing 0.62$ Estimated same pricing as 1215bar.A6. CHROMIUM-MOLYBDENUM (CHROMOLY) STEELSA6.141XX41xxBar Injector BodyA-Steel-41XXS, Bar 0.78$ Assigned same rate as A-Steel-4140, Bar 0.875-2.75"Chrome-Moly-Vanadium Steel 32CrMoV13Bar Bearings, Crank shafts MA-Steel-CrMoV, Bar 0.98$ Composition analysis plus surcharge4140RH 42CrMoS4Bar Crankshafts, axle journals, gears, pushrods. A-Steel-4140, Bar 0.78$ Composition analysis plus surcharge4130 Spring Steel Heat-Treatable C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25Coil Direct Injector Spring Clips HC-Steel-4130, Coil1.18$ Surrogate pricing based on 4130 0.040"-0.125"4130 C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25Coil, 0.04" to 0.125"HC-Steel-4130, Coil0.04"-0.125"1.18$ Online Metals, Aircraft Spruce& Specialty Co. & Specialty Co.4130 Tight Thickness Tolerance. C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25Coil, 0.05" to 0.08",Tight ThicknessToleranceHC-Steel-4130, Coil0.04"-0.08"2.79$ KmacA7. NICKLE-CHROMIUM-MOLYBDENUM STEELSA7.143XXNi 1.82%, Cr 0.50-0.80%, Mo 0.25%300M SAE 4340Mod Vacuum melted highstrength, super alloy.Drive shafts, Con. Rods MA-Steel-300M, Bar 0.89$ Composition analysis plus surchargeNi-Chrome-Moly SAE 4330/4340 Bar 1-7" Planetary Gear Carrier, Shafts MA-Steel-43XXM, Bar 1.08$ Online Metals, Metals Express,Hi Tech Metals quoteA7.4 86XXNi 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 gearcomponents.A-Steel-8620, Bar 0.70$ Composition analysis plus surchargeA9. CHROMIUM STEELSA9.451XXCr 0.80% or 0.87% or 0.92% or 1.00% or1.05%.SAE 5115 C0.15, Si0.25, Mn0.50, Cr0.60, BarA-Steel-51XX, Bar 1.00$ Surrogate pricing based on "A-Steel-5140, Bar"SAE 5140/5145Bar Gears, ShaftsA-Steel-5140, Bar 1.00$ Kmac, Raker, Continental SteelQuoteA9.551XXXCr 1.02%, C 1.00% Min.Chromium Steel, High Carbon,Bearing Grade, Unpolished MillFinished, AnnealedSAE 52100Bar >0.5" Bearing RacesA-Steel-52100 Bar 1.00$ Kmac, Raker, Continental SteelQuoteA10. CHROMIUM-VANADIUM STEELSA10.161XXCr 0.60% or 0.80% or 0.95%, V 0.10% or0.15%SAE 6150Bar 1-8" Park pawl, park gear0.67$ KmacCarbon 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 SpecificationSupplementalSpecificationInformationApplication Examples Material Class Information Reference SourceA. Carbon/Alloy SteelB. HSLA & Micro AlloyC. Stainless SteelD. Cast IronH. Titanium AlloysG. Magnesium AlloysJ. Copper AlloysF. Powder MetalE. Aluminum AlloysM.Q. ThermoplasticsR Thermosets.S. Thermoplastic Elast.P.N.L Cobalt Alloys.O.K. Nickel AlloysT.U Automotive Fluids.V. Plating & CoatingsW Misc.X.Y.File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3E.1, Page 1of 7Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.1 Material Costing Database ExcerptAppendix E.1Printed:12/9/2009Active Rate2008Cat. Item Material Description Industry SpecificationSupplementalSpecificationInformationApplication Examples Material Class Information Reference SourceA. Carbon/Alloy SteelB. HSLA & Micro AlloyC. Stainless SteelD. Cast IronH. Titanium AlloysG. Magnesium AlloysJ. Copper AlloysF. Powder MetalE. Aluminum AlloysM.Q. ThermoplasticsR Thermosets.S. Thermoplastic Elast.P.N.L Cobalt Alloys.O.K. Nickel AlloysT.U Automotive Fluids.V. Plating & CoatingsW Misc.X.Y.B. HIGH STRENGTH LOW ALLOY (HSLA) and MICRO ALLOY STEELSB2. Micro Alloy SteelsA2.1Mn 1.75%C70S6C0.72%, Si0.22%, Mn0.49%, S0.062%,V0.04%Typical Air CooledForging SteelForged fractured split rods MA-Steel-C70S6, Bar 0.70$ Composition analysis plus surcharge36MnVS4BarCrankshafts, Cracked Forged Rods, Short andLong-shaft Ball Points, threaded heavy dutyanchor bolts.MA-Steel-MnVS, Bar 0.73$ Composition analysis plus surchargeC. STAINLESS STEELS (SAE100-600Series)C1. 300 Series - Austenitic Chromium-Nickel AlloysC1.1304General Purpose304Bar Valves and Tubing S-Steel-304, Bar 1.65$ MEPS, stainlesssteel.com, purchasing.com304/304LCoil Exhaust Systems, Fuel tanks S-Steel-304, Coil 1.64$ MEPS, stainlesssteel.com, purchasing.com304/304LSheet or Cast Housings for Catalytic Converters andTurbochargers.S-Steel-304, Cast 1.39$ MEPS, stainlesssteel.com, purchasing.com304Tube Fuel RailS-Steel-304, Tube 1.65$ Estimate, same pricing as 304BarC1.1.1316Mo added to increase corrosion resistance.316Bar Valves and Tubing S-Steel-316, Bar 2.44$ MEPS, stainlesssteel.com, purchasing.com316/316L C reduced for weldability CoilS-Steel-316, Coil 2.72$ MEPS, stainlesssteel.com, purchasing.com316/316L C reduced for weldability Cast/Sheet Housingsfor Catalytic Converters andTurbochargers.S-Steel-316, Cast 2.82$ MEPS, stainlesssteel.com, purchasing.comC1.1.2309/309SCR & 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 Holder 1.5 x $ "S-Steel-316, Cast"C1.1.5303S added to improve machining.303Se Se (Selenium) added for better machinedsurfaces.303Bar Valves and Tubing S-Steel-303, Bar 1.55$ MEPS, stainlesssteel.com, purchasing.com303LBar Valves and Tubing S-Steel-303L, Bar 1.65$ MEPS, stainlesssteel.com, purchasing.comC1.1.6301Cr and Ni lowered to increase work hardening.C1.1.7 MISC.21-2N/21/4N (EV8) Austenitic Precipitation HardeningChromeManganese 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 Price from Bundy with trend analysis.C2. 400 Series Ferritic Chromium AlloysC.2.1.1442Cr Increased to improve scaling resistance,422Bar Intake & Exhaust Valves S-Steel-422, Bar 7.56$ Point Price from Power Plant Services with trend analysis.Harden by cold working, can not be hardened by heattreating, Non Magnetic in annealed condition. Excellent corrosionresistance and usually good formability.Can not be hardened through heat treatment and onlymoderately hardened by cold working. The are magnetic, havegood ductility and resistance to corrosion and oxidation.File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3E.1, Page 2of 7Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.1 Material Costing Database ExcerptAppendix E.1Printed:12/9/2009Active Rate2008Cat. Item Material Description Industry SpecificationSupplementalSpecificationInformationApplication Examples Material Class Information Reference SourceA. Carbon/Alloy SteelB. HSLA & Micro AlloyC. Stainless SteelD. Cast IronH. Titanium AlloysG. Magnesium AlloysJ. Copper AlloysF. Powder MetalE. Aluminum AlloysM.Q. ThermoplasticsR Thermosets.S. Thermoplastic Elast.P.N.L Cobalt Alloys.O.K. Nickel AlloysT.U Automotive Fluids.V. Plating & CoatingsW Misc.X.Y.C3. 400 Series Martensitic Chromium AlloysC3.1.5440CC increased for highest hardness. Crincreased for corrosion resistance.Bar Intake & Exhaust Valves S-Steel-440C, Bar 4.56$ Point Price from AK Steel withtrend analysis.440B C decreases slightly to improve toughness.440A Same as 440B, only more so.D. CAST IRONSD1. Nodular/Ductile Cast IronNodular / Ductile Iron (80-55-06) ASTM A536-80-55-06$0.90-$1.2/lb finishedcastingCrankshaft, blocks Nodular Iron, Cast 0.35$ AISI, MEPSNodular / Ductile Iron (100-70-03) ASTM A536-100-70-03$0.90-$1.2/lb finishedcastingHigh Strength Cam shafts i.e.., driving HP fuelpumps.Nodular Iron,Gr100/70/03, Cast0.42$ Estimate base on ASTM A536-80-55-06Ni-resist cast iron, D5S D5S, ASTM A-439-84Housing - Turbo Exhaust NiResist Iron, D5S, Cast 3.50$ Estimate from Turbocharger Industry ExpertSilicon Molybdenum Cast Iron 4% Si & 1% MoHousing-Block Center, Turbo Support SiMo Ductile Iron, Cast 0.60$ Estimate from Turbocharger Industry ExpertD2. Malleable Cast IronsMalleable Cast Iron$0.90-$1.2/lb finishedcastingCrankshaft, camshafts, blocks Malleable Cast Iron 0.41$ AISI, MEPSD3. Grey Cast IronGrey Cast Iron SAE J431 Grade 3000 (3.1-3.4C, 1.9-2.3Si,Mn 0.60-0.90)Engine BlocksGrey Iron, Cast 0.35$ Estimate same pricing as ASTMA536-80-55-06E. ALUMINUM ALLOYSE1. Wrought AlloysE1.1 2XXX Al-Cu Alloys2024 2024-T3/T4/T351 Bar Ø0.5-2.5"Aluminum-2024, Bar 2.38$ Aircraft Spruce & Specialty Co. & Specialty Co., OnlineMetals, Industrial Metal2024 2024-T3/T4/T351 Sheet, 0.032"-0.125"Aluminum-2024, Sheet 3.41$ Online Metals, Kmac, AirpartsE1.2 3XXX Al-Mn Alloys3003, 3005, 3012 Aluminum MagnesiumBraze-clad welded radiator tubes, heater cores, radiator, heaterand evaporative fins, heater inlet and outlet tubes, oil coolers,and air conditioner liquid lines, radiator heater and evaporativeparts, extruded condenser tubes.Aluminum-3000S, Coil 0.84$ Aluminum.com, AMM reference.3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.032-0.125"(0.75-3.15mm)Heat Exchangers Aluminum-3003, Coil A 1.41$ Aluminum.com, AMM reference.3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.003-0.009"(0.075-0.22mm)Heat Exchangers Aluminum-3003, Coil B 1.93$ Lynch EstimateE1.3 4XXX Al-Si Alloys4032 4032-T651Bar Ø1.0-2.5"Aluminum-4032, Bar 1.44$ KmacE1.4 5XXX Al-Mg Alloys5052H32 5052 H32Coil 0.025-0.125"Aluminum-5052, Coil 1.52$ Online Metals, Metal Depot, Airparts, Enco, All MetalsE1.5 6XXX Al-Mg-Si Alloys6062 6062-T6511 Bar Ø0.5-1.5" Spool valvesAluminum-6062, Bar 1.45$ Online Metals6061 6061-T6511 Bar Ø0.5-3.0"Aluminum-6061, Bar 1.50$ Metals Express, Aircraft Spruce & Specialty Co., All Metals,Metal ConnectionE1.8 Misc3003-H14 Clad 4XXX Aluminum-Manganese Cladded Tube Seamless welded tube -thickness 0.012-0.02"(0.3-0.5mm)Heat Exchangers Cladded Aluminum3003, Tube2.28$ Lynch EstimateTypical 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> Thermallytreated, usually solution heat-treated, quenched and precipitation hardened.Are hardenable through heat treatment. They are magnetic. The resistance corrosion in mild environments. They havefairly good ductility, and some can be heat treatedto Tensile Strengths exceeding 200kpsi.File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3E.1, Page 3of 7Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.1 Material Costing Database ExcerptAppendix E.1Printed:12/9/2009Active Rate2008Cat. Item Material Description Industry SpecificationSupplementalSpecificationInformationApplication Examples Material Class Information Reference SourceA. Carbon/Alloy SteelB. HSLA & Micro AlloyC. Stainless SteelD. Cast IronH. Titanium AlloysG. Magnesium AlloysJ. Copper AlloysF. Powder MetalE. Aluminum AlloysM.Q. ThermoplasticsR Thermosets.S. Thermoplastic Elast.P.N.L Cobalt Alloys.O.K. Nickel AlloysT.U Automotive Fluids.V. Plating & CoatingsW 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 Alloys319 T5 Al-3.5Cu-6Si Hypoeutectic/Perm. Manifolds, cylinder heads, blocks, internal enginepartsAluminum-A319-T5, Cast1.15$ CRU group, AMM reference332 / F132 8.5-10Si, 2.0-4.0Cu, Ni0.10 Hypereutectic,commongrade, large recycledcomposition (Die.)HypoeutecticAluminum-332, Cast 1.24$ CRU group, AMM reference356 T6 or A356 7Si-0.3 Mg alloy Hypoeutectic (Perm.) Engine blocks, flywheel, oil pan, pump bodies, cylheads, manifolds, transmission casesAluminum-356-T6, Cast 1.20$ CRU group, AMM referenceA380.1 Al-9Si-3Cu(Fe) Hypoeutectic (Die.) Blocks, transmission housings/parts, fuelmetering devices, oil pump cyl heads,Aluminum-A380, Cast 1.10$ CRU group, AMM referenceB380 Al-9Si-3Cu(Fe) Hypoeutectic (Die) Blocks, transmission housings/parts, fuelmetering devices, oil pump cyl heads,Aluminum-B380, Cast 1.18$ CRU group, AMM reference384Eutectic (Die) Pistons, automatic transmissions Aluminum-384, Cast 1.14$ CRU group, AMM referenceB390.0 Hypereutectic aluminum-silicon Hypereutectic (Die.) High-wear applications such as ring gears andinternal transmission parts, Hypereutectic pistons,cylinder blocksAluminum-B390, Cast 1.20$ CRU group, AMM referenceA383 AlSi10Cu2Hypoeutectic (Die.) Blocks3HA Piston Alloy AlSi12Cu4Ni2MgF. POWDER METALS (Classification per MPIF Standard35)F1. PM Structural Materials: Ferrous and Non-ferrousCrank timing sprockets or gears, cam shaft timingsprocket or gears, Transmission clutch hubs, ATMplanetary ring gear, Cam lobe on composite camshaft, impellers.Ferrous MaterialsF1.1 Iron and Carbons SteelSintered Powdered Metal (Ironbase powder alloy)SAE 1541PM-SMF-Iron Base 1.00$F1.10 Stainless Steel - 300 Series Alloy304/304LPM-SMF-SS304 4.92$ 3x Cost of 304 Coil - reference above316 Stainless SS-316N2, 17Cr,12Ni,2.5Moρ=6.5g/cm^3,UTS=60ksi Good Corrosion Resistance, Appearance PM-SMF-SS316 8.16$ 3x Cost of 316 Coil - reference aboveF1.11 Stainless Steel - 400 Series Alloy430 Stainless SS-430N2, 17Crρ=7.1g/cm^3,UTS=60ksi Good Corrosion Resistance, Appearance410 Stainless SS-41, 13Cr, 0.8Si, 0.8Mnρ=6.1g/cm^3,UTS=66.7ksiDI SolenoidsPM-SMF-SS410 4.50$ Need Pricing ConfirmationF1.12 MiscellaneousNon-Ferrous MaterialsF1.21 Aluminum and Aluminum AlloysPM Aluminum - StructuralComponents4.4Cu/0.5Mg/0.6SiYs/UTS in ksi: w. T4 HT,31/38 w. T6 HT47.5/48.1Cam CapsPM-SMNF-Aluminum $ 3.50F2. P/F Steel Part MaterialsF2.0 Carbon SteelPowdered forged HS150/160Connecting Rods PF-SMF-HS150/160 0.70$ Composition analysis plus surchargeFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3E.1, Page 4of 7Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.1 Material Costing Database ExcerptAppendix E.1Printed:12/9/2009Active Rate2008Cat. Item Material Description Industry SpecificationSupplementalSpecificationInformationApplication Examples Material Class Information Reference SourceA. Carbon/Alloy SteelB. HSLA & Micro AlloyC. Stainless SteelD. Cast IronH. Titanium AlloysG. Magnesium AlloysJ. Copper AlloysF. Powder MetalE. Aluminum AlloysM.Q. ThermoplasticsR Thermosets.S. Thermoplastic Elast.P.N.L Cobalt Alloys.O.K. Nickel AlloysT.U Automotive Fluids.V. Plating & CoatingsW Misc.X.Y.G. MAGNESIUM WROUGHT & CASTING ALLOYSG2. Cast AlloysG2.1AZ91AZ91 AZ91D Mg Al9 Zn1Valve CoversMagnesium-AZ91D,Cast2.42$USGS, AMM Reference, PurchasingCentracore, Mark Luchese (09/1709) Low Volume RateH. TITANIUM WROUGHT & CASTING ALLOYSH1. Wrought AlloysTitanium (Sponge Only)Titanium-Sponge, Cast 4.71$ USGSTitanium (6AL V4)Bar High Pressure Bellows Pump Titanium-6AL4V, Bar 34.37$ LongbowTitanium (6AL V4)PlateTitanium-6AL4V, Plate 43.91$ LongbowH2. Cast AlloysTitanium (6AL V4)IngotTitanium-6AL4V, Cast 21.30$ LongbowJ. 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 Bronzebushings, pump fixtures, pump impellers, fuelpump bushings, thrust washers, insert bearings,gears, valves and valve components, etc.Bronze-932, Bar 2.56$ InfoMine for copper plus composition analysisC89320 Lead Free Replacement to C93200 89%Cu, 6%Sn,and5%BiTurbocharger Spindle Bushings (Floating Type) Bronze-89320, Bar 2.56$ Estimate based on C93200Oilite Bronze Bearing Alloy SAE8411" Round Bar5.31$ Wisco AlloysJ6.4 Aluminum Bronze(LC-VH, T=VH, C/E=P RS=M, H/W=VH)ASTM C63000, C63020 Nickel Aluminum BronzeValve stems and trim, bearings and bushings,fasteners, gearsNi-Al-Bronze-630000,Bar2.44$ InfoMine for copper plus composition analysisJ6.12 Silicon Brasses (LC=? , T=? , C/E=? , RS=?,H/W=?)C87500 (500) Silicon Brass, 82-4Si-14ZnBearings, gears, impellers, rocker arms, valvestems, brush holders, bearing races, small boatpropellers.Si-Brass-87500, Bar 2.11$ InfoMine for copper plus composition analysisCDA 673 - Silicon ManganeseBrassC67300BarSi-Brass-67300, Bar 3.71$ Atlas Bronze Quote (quote price plus copper trend line)J6.13 Brass GeneralC36000 CDA 360Fluid connectors, threaded inserts for plasticparts, sensor bodies, thermostat partsBrass-36000, Bar 1.70$ InfoMine for copper plus composition analysisJ6.14 Cooper GeneralCopper >99.0% PureWire harnesses Copper-Pure, Wire 2.45$ InfoMineK. NICKEL WROUGHT & CASTING ALLOYSK1. Wrought AlloysK1.1 Inconel®Inconel® 751/HEV3Bar Exhaust Valves Inconel-751, Bar 12.22$ Point price from Special MetalsWV with trend analysis.Inconel® 713 CoilCoil Heat Shields, Turbo Inconel-713C, Coil 6.00$ Estimate from Turbocharger Industry ExpertNickel Alloy - Internal Turbo Parts GeneralCoil Heat Shields, Turbo Nickel Alloy Gen, Cast 5.00$ Need Material and Pricing ConfirmationInconel® 713 CoilCastInconel-713, Cast 6.00$ Estimate from Turbocharger Industry ExpertFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3E.1, Page 5of 7Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.1 Material Costing Database ExcerptAppendix E.1Printed:12/9/2009Active Rate2008Cat. Item Material Description Industry SpecificationSupplementalSpecificationInformationApplication Examples Material Class Information Reference SourceA. Carbon/Alloy SteelB. HSLA & Micro AlloyC. Stainless SteelD. Cast IronH. Titanium AlloysG. Magnesium AlloysJ. Copper AlloysF. Powder MetalE. Aluminum AlloysM.Q. ThermoplasticsR Thermosets.S. Thermoplastic Elast.P.N.L Cobalt Alloys.O.K. Nickel AlloysT.U Automotive Fluids.V. Plating & CoatingsW Misc.X.Y.L. COBALT WROUGHT & CASTING ALLOYSL1. Wrought AlloysL1.1 Stellite®Stellite® 6 Base Co, Cr 27-32%, W4-6%, C0.9-1.4%,Others Ni, Fe, Si, Mn, MoBar Exhaust Valves Stellite 21.00$Q. THERMOPLASTIC POLYMNERSQ1. Polyamide (PA/Nylon)Nylon 6 PA6Nylon6, Inject. 1.65$ IDES, Plastic NewsNylon 6 (15 % glass) PA6 GF15Air cooler tube outlet Nylon6-15GF, Inject. 1.59$ IDES, Plastic News, Plastic TechnologyNylon 6 (30 to 35% glass) PA6 GF30Vacuum reservoir, Intake manifold Nylon6-30GF, Inject. 1.76$ IDES, Plastic News, Plastic TechnologyNylon 66 PA66Fuel injector connector, hose asm end - pump toturbo, chain tension guidesNylon66, Inject. 1.74$ IDES, Plastic NewsNylon 66 (30 to 35% glass) PA66 GF30Intake manifold, cylinder cover, cooler asm endcapsNylon66-30GF, Inject. 1.54$ IDES, Plastic NewsNylon 66 (50% glass) PA66 GF50cooler asm end caps Nylon66-50GF, Inject. 1.54$ IDES, Plastic NewsNylon 66, 40% Fibrous MineralReinforcedPA66 FMR40% GMNA Spec PA66 060 Direct Injection Connectors Nylon66-40FMR, Inject. 1.54$ Estimate based on PANylon 12 PA12Reservior tubeNylon12, Inject. 3.03$ IDES, Plastic News, Plastic TechnologyNylon 12, 30% glass PA12, GF30PCV Hose Intake End3.41$ IDES, Plastic News, Plastic TechnologyQ3. PolyethyleneHDPE Copolymer - blowmolding HDPERubberized blow molded air induction ducts andcouplings.HDPE BM Grade 0.72$Q4. Polybutylene Terephthalate (PBT)Polybutylene Terephthalate PBT GF20Silencer Air by-pass PBT-GF20, Inject. 1.46$ IDES, Plastic NewsQ5. Acrylonitrile Butadiene Styrene (ABS)ABSBeta patch for battery closeout0.72$ Plastic NewsQ6. Polypropylene (PP)Random copolymer blow moldinggrade.PPHigh strength blow molded air induction ducts. HD Polypro 0.87$Q9. Polyvinylchloride (PVC)Blended NBR-PVCRubberized blow molded air induction ducts andcouplings.NBR-PVC 1.27$Q9. MiscellaneousTeflon® PolytetrafluoroethylenePTFE, Inject. 6.70$ IDES, Plastic NewsR. THERMOSET POLYMERSR1 Hydrocarbon, Unsaturated.Natural rubber / TSR20 NRHoses, O-rings, gaskets, tubes Thermoset-NR 2.14$ CMAI, Rubber Statistical BulletinSynthetic poly-isoprene rubber IRHoses, O-rings, gaskets, tubes Thermoset-IRStyrene butadiene rubber SBRHoses, O-rings, gaskets, tubes Thermoset-SBR 1.32$ CMAI, Rubber Statistical BulletinButadiene rubber BRHoses, O-rings, gaskets, tubes Thermoset-BR 0.65$ CMAIPolubutadiene rubber PBRHoses, O-rings, gaskets, tubes Thermoset-PBR 0.82$ The Innovation GroupPolubutadiene rubber - glass filled PBR GF20Auxiliary water pump housing Thermoset-PBR-GF20 1.17$ The Innovation Group, PlasticsNews (for delta)Butyl rubber IIRHoses, O-rings, gaskets, tubes Thermoset-IIR 1.37$ The Innovation GroupChloro- and bromo- butyl rubber CIIR, BIIRHoses, O-rings, gaskets, tubesFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3E.1, Page 6of 7Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.1 Material Costing Database ExcerptAppendix E.1Printed:12/9/2009Active Rate2008Cat. Item Material Description Industry SpecificationSupplementalSpecificationInformationApplication Examples Material Class Information Reference SourceA. Carbon/Alloy SteelB. HSLA & Micro AlloyC. Stainless SteelD. Cast IronH. Titanium AlloysG. Magnesium AlloysJ. Copper AlloysF. Powder MetalE. Aluminum AlloysM.Q. ThermoplasticsR Thermosets.S. Thermoplastic Elast.P.N.L Cobalt Alloys.O.K. Nickel AlloysT.U Automotive Fluids.V. Plating & CoatingsW Misc.X.Y.R2. Hydrocarbon SaturatedEthylene propylene (diene) rubber EPM/EPDMHoses, O-rings, gaskets, tubes Thermoset-EPDM 1.83$ The Innovation GroupR3. NitrileNitrile butadiene rubber NBRHoses, O-rings, gaskets, tubes Thermoset-NBR 1.27$ The Innovation GroupR8. FluorocarbonFluoro elastomer FKMERG valve seals Thermoset-FKM 12.50$ Plastics NewsR10. PolyimidePolyimide - Vespel SP-21 PI 30%Carbon filledthrust washers, bearings and seals — low-frictionproperties, work with or without lubrication.Thermoset-VespelSP21CF3035.18$ PT online, Plastic News - Trendline from surrogate materialsPolyimide - Vespel SP-21 PI 30%Glass filledThermoset-VespelSP21GF3024.36$ PT online, Plastic News - Trendline from surrogate materialsR12. PolyurethanePolyurethane elastomer, esterbasedAUHoses, O-rings, gaskets, tubes Thermoset-AU 1.77$ Rubber and Plastics NewsR13. SiliconeSilicone rubber MVQHoses, O-rings, gaskets, tubesThermoset-MVQ4.50$R14. MiscellaneousSBR Tubing w. FiberReinforcementSBR Reinforced TubingSBR-Fiber Rein.,Extruded1.85$ 1.40 x $SBRSBR Tubing w. MetalReinforcementSBR Reinforced TubingSBR-Metal Rein.,Extruded2.24$ 1.70 x $SBRSBR Tubing w. FiberReinforcement and outer wrap.SBR Reinforced TubingSBR-Fiber Rein. W.Outer Wrap, Extruded2.05$ 1.55 x $SBRS. THERMOPLASTIC ELASTOMERSOlefinic Syn Rubber M-group Synthetic Hoses, O-rings,gaskets, tubes TPE-PP/EPDM, Inject. 0.99$ Plastics NewsOlefinic TPE+TD33Cooling Fan Shroud1.04$ Plastics News, HutsmannU. AUTOMOTIVE FLUIDSEngine Oil - Synthetic (Price/Quart)Engine Oil-Synthetic 1.40$ Need Pricing Confirmation SourceEngine Oil - Regular (Price/Quart)Engine Oil-Regular 0.60$ Need Pricing Confirmation SourceV. PLATINGS & COATINGSV.1 Aluminum CladdingAluminum-Silicon Cladding 3003 Sheet w. 4047 CladdingSingle Cladding, Combined MaterialThickness <0.060"Thickness tolerance10% Base MaterialThicknessOil Coolers, Radiators, etc Aluminum-3003/4047A,Cladding1.65$ Sue received feedback from Alcoa (3/27/09)Aluminum-Silicon Cladding 3003 Sheet w. 4047 CladdingSingle Cladding, Combined MaterialThickness >0.060"Thickness tolerance10% Base MaterialThicknessOil Coolers, Radiators, etc Aluminum-3003/4047B,Cladding2.10$ Sue received feedback from Alcoa (3/27/09)Brake and Oil Line Platings GALFAN Hot Dipped Thickness 4mil or 0.1mmGALFAN 0.56$ http://metalprices.com/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 investigation. Elementalcompositions were thencompared and deltas defined to determine cost differences. Since the cost differences are calculatedfrom the elemental deltas, it was necessary to obtain the cost of the base elements. The costs of base elements such as zinc, copper and magnesium are readily available andpublished in several websites. Next, the cost perpound 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 point to establish a price perpound of the material underinvestigation. 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 various manufacturerswebsites to alert theircustomers of pending price fluctuations.File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA 1-3E.1, Page 7of 7Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.2 Labor Costing Database ExcerptAppendix E.2Printed:12/9/2009Production Year Start (Baseline)2008ActiveRate2008MeanHourlyWageIndirectLaborRateRatioILRR"%"IndirectLaborContribution$/HourMROLaborRateRatioMLRR"%"MRO LaborContribution$/HourFringeAllocation"%"FringeContribution$/HourTotalLaborRate$/HourI. Motor Vehicle Parts Manufacturing - NAICS 336300Default orAverage Rate$16.4249.42%$8.1816.16%$2.6752.00%$14.18$41.451 51-2022 Electrical and ElectronicEquipment AssemblersAssemble or modify electrical or electronic equipment,such as computers, test equipment telemeteringsystems, electric motors, and batteries.Sensors, Controllers,PCMElectrical Assembly $29.69 $12.85 40%$5.1412%$1.54 52% $10.16 $29.69US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm2 51-2023 ElectromechanicalEquipment AssemblersAssemble or modify electromechanical equipment ordevices, such as servomechanisms, gyros,dynamometers, magnetic drums, tape drives, brakes,control linkage, actuators, and appliances.Electro MechanicalAssemblies, Motors,Actuators, etc.Electromechanical Assembly $37.35 $16.06 40%$6.4213%$2.09 52% $12.78 $37.35US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm3 51-2031 Engine and Other MachineAssemblersConstruct, assemble, or rebuild machines, such asengines, turbines, and similar equipment used in suchindustries as construction, extraction, textiles, andpaper manufacturing.Complex Assembly Complex Assembly $42.90 $17.64 43%$7.5917%$3.00 52% $14.68 $42.90US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm4 51-2092 Team Assemblers Work as part of a team havingresponsibility forassembling an entire product or component of aproduct. Team assemblers can perform all tasksconducted by the team in the assembly process androtate through all or most of them rather than beingassignedGeneral Assembly General Assembly $35.51 $13.66 52%$7.1019%$2.60 52% $12.15 $35.51US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm5 51-2093 Timing Device Assemblers,Adjusters and CalibratorsPerform precision assembling or adjusting, withinnarrow tolerances, of timing devices, such as watches,clocks, or chronometers. Exclude "Watch Repairers"(49-9064).Assembly operationsrequiring feedback duringassemblyPrecision Assembly $25.74 $11.07 40%$4.4313%$1.44 52% $8.81 $25.74US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm6 51-2099Assemblers and Fabricators,All OtherAll assemblers and fabricators not listed separately.Stand alone completeassembly stations.Work Cell Assembly $49.78 $19.38 50%$9.6919%$3.68 52% $17.03 $49.78US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm7 51-4011 Computer-ControlledMachine Tool Operators(Metal & Plastic)Operate computer-controlled machines or robots toperform one or more machine functions on metal orplastic work pieces.CNC Stations, CNC Operator $35.70 $15.25 42%$6.4112%$1.83 52% $12.21 $35.70US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm8 51-4021 Extruding and DrawingMachine setters, Operators,and Tenders, Metal & PlasticSet up, operate, or tend machines to extrude or drawthermoplastic or metal materials into tubes, rods, hoses,wire, bars, or structural shapes.Extrusion, Seals,Gaskets, Grommets, etc.(Considered to be mostlypolymer materials withexception of some veryductile metals)Extruding/Drawing Operator $54.35 $18.92 67%$12.6822%$4.16 52% $18.59 $54.35US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm9 51-4022 Forging Machine Setters,Operators, and Tenders,Metal and PlasticSet 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%$7.9119%$2.78 52% $13.18 $38.52US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm10 51-4031 Cutting, Punching, andPress Machine Setters,Operators and Tenders,Metal and PlasticSet up, operate, or tend machines to saw, cut, shear,slit, punch, crimp, notch, bend, or straighten metal orplastic material.Stamping & Forming,Metal or PlasticCut/Punch/Forming Operator $42.18 $16.04 54%$8.6619%$3.05 52% $14.43 $42.18US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm11 51-4032 Drilling and Boring MachineTool Setters, Operators, andTenders, Metal and PlasticSet up, operate, or tend drilling machines to drill,bore,ream, mill, or countersink metal or plastic work pieces.Smaller MachiningStations and/or with lessautomationDrilling/Boring Operator $43.35 $18.52 40%$7.4114%$2.59 52% $14.83 $43.35US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm12 51-4033 Grinding, Lapping, Polishing, and Buffing Machine ToolSetters, Operators, andTenders, Metal and PlasticsSet up, operate, or tend grinding and related toolsthatremove excess material or burrs from surfaces, sharpenedges or corners, or buff, hone, or polish metal orplastic work pieces.Smaller Grinding/HoningStations and/or with lessautomationGrinding/Polishing Operator $44.48 $17.63 50%$8.8216%$2.82 52% $15.22 $44.48US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm13 51-4034 Lathe and Turning MachineTool Setters, Operators, andTenders, Metal and PlasticSet up, operate, or tend lathe and turning machinestoturn, bore, thread, form, or face metal or plasticmaterials, such as wire, rod, or bar stock.Smaller Turning Stationand/or with lessautomationLathe/Turning Operator $37.60 $16.49 38%$6.2712%$1.98 52% $12.86 $37.60US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm14 51-4035 Milling and Planing MachineSetters, Operators, andTenders, Metal and Plastic.Set up, operate, or tend milling or planing machinestomill, plane, shape, groove, or profile metal or plasticwork pieces.Milling Operations Milling/Planing Operator $35.37 $15.41 40%$6.1611%$1.70 52% $12.10 $35.37US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htmInformation Source



# ItemSOCSCode(BLS)Direct Labor Title(BLS)Direct Labor Description (BLS)Typical ApplicationAssociationLabor ClassificationFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.2, Page 1 of 4Author: Greg Kolwich(248) 373-6000 Ext 2411APPENDIX E.2 Labor Costing Database ExcerptAppendix E.2Printed:12/9/2009Production Year Start (Baseline)2008ActiveRate2008MeanHourlyWageIndirectLaborRateRatioILRR"%"IndirectLaborContribution$/HourMROLaborRateRatioMLRR"%"MRO LaborContribution$/HourFringeAllocation"%"FringeContribution$/HourTotalLaborRate$/HourInformation Source



# ItemSOCSCode(BLS)Direct Labor Title(BLS)Direct Labor Description (BLS)Typical ApplicationAssociationLabor Classification15 51-4072 Molding, Core making, andCasting Machine Setters,Operators, and Tenders,Metal & PlasticSet up, operate, or tend metal or plastic molding,casting, or core making machines to mold or cast metalor thermoplastic parts or products.Molding and CastingOperatorsMold/Cast/Sinter Operator $43.52 $15.15 66%$10.0023%$3.48 52% $14.89 $43.52US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm16 51-4081 Multiple Machine ToolSetters, Operators, andTenders, Metal and Plastic.Set up, operate, or tend to more than one type ofcutting or forming machine tool or robot.Will not use, too general andoverlap with other categories.$44.85 $17.46 52%$9.0817%$2.97 52% $15.34 $44.85US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm17 51-4122 Welding, Soldering, andBrazing Machine Setters,Operators, and Tenders.Set up, operate, or tend welding, soldering, or brazingmachines or robots that weld, braze, solder, or heattreat metal products, components, or assemblies.Include workers who operate laser cutters or laser-beammachines.Various WeldingOperationsWelding/Soldering Operator $44.96 $18.72 42%$7.8616%$3.00 52% $15.38 $44.96US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm18 51-4191 Heat Treat EquipmentSetters, Operators, andTenders, Metal and PlasticSet up, operate, or tend heating equipment, such asheat-treating furnaces, flame-hardening machines,induction machines, soaking pits, or vacuum equipmentto temper, harden, anneal, or heat-treat metal or plasticobjects.Heat Treat Heat Treat Operator $46.52 $16.28 69%$11.2319%$3.09 52% $15.92 $46.52US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htm19 51-4193Plating and Coating MachineSetters, Operators, andTenders, Metal and PlasticSet up, operate, or tend plating or coating machinestocoat metal or plastic products with chromium, zinc,copper, cadmium, nickel, or other metal to protect ordecorate surfaces. Include electrolytic processes.Plating & Finishes Plating/Coating Operator $55.17 $20.86 60%$12.5214%$2.92 52% $18.87 $55.17US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336300 - Motor Vehicle Parts Manufacturinghttp://www.bls.gov/oes/current/naics4_336300.htmFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.2, Page 2 of 4Author: Greg Kolwich(248) 373-6000 Ext 2411APPENDIX E.2 Labor Costing Database ExcerptAppendix E.2Printed:12/9/2009Production Year Start (Baseline)2008ActiveRate2008MeanHourlyWageIndirectLaborRateRatioILRR"%"IndirectLaborContribution$/HourMROLaborRateRatioMLRR"%"MRO LaborContribution$/HourFringeAllocation"%"FringeContribution$/HourTotalLaborRate$/HourInformation Source



# ItemSOCSCode(BLS)Direct Labor Title(BLS)Direct Labor Description (BLS)Typical ApplicationAssociationLabor ClassificationII. Motor Vehicle Manufacturing - NAICS 336100Default orAverage Rate$21.5448.00%$10.2114.56%$3.08160.00%$55.73$90.561 51-2022 Electrical and ElectronicEquipment AssemblersAssemble or modify electrical or electronic equipment,such as computers, test equipment telemeteringsystems, electric motors, and batteries.Electronic SubassemblyBuild-Up/AssemblyElectrical Assembly-OEM $71.82 $18.54 38%$7.0511%$2.04 160% $44.20 $71.82US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm2 51-2031 Engine and Other MachineAssemblersConstruct, assemble, or rebuild machines, such asengines, turbines, and similar equipment used in suchindustries as construction, extraction, textiles, andpaper manufacturing.Complex Assembly:Engines, TransmissionsComplex Assembly-OEM $97.34 $26.18 34%$8.909%$2.36 160% $59.90 $97.34US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm3 51-2092 Team Assemblers Work as part of a team havingresponsibility forassembling an entire product or component of aproduct. Team assemblers can perform all tasksconducted by the team in the assembly process androtate through all or most of them rather than beingassignedGeneral Assembly General Assembly-OEM $83.31 $20.28 44%$8.9214%$2.84 160% $51.27 $83.31US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm4 51-2099Assemblers and Fabricators,All OtherAll assemblers and fabricators not listed separately.Stand alone completeassembly stations.Work Cell Operator-OEM $95.87 $24.42 38%$9.2813%$3.17 160% $59.00 $95.87US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm5 51-4011 Computer-ControlledMachine Tool Operators(Metal & Plastic)Operate computer-controlled machines or robots toperform one or more machine functions on metal orplastic work pieces.CNC Stations, CNC Operator-OEM $68.07 $17.00 42%$7.1412%$2.04 160% $41.89 $68.07US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm6 51-4022 Forging Machine Setters,Operators, and Tenders,Metal and PlasticSet up, operate, or tend forging machines to taper,shape, or form metal or plastic parts.Cold or Hot Forgings,Metal or PlasticForging Operator-OEM $58.96 $12.74 58%$7.3920%$2.55 160% $36.28 $58.96US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm7 51-4031 Cutting, Punching, andPress Machine Setters,Operators and Tenders,Metal and PlasticSet up, operate, or tend machines to saw, cut, shear,slit, punch, crimp, notch, bend, or straighten metal orplastic material.Stamping & Forming,Metal or PlasticCut/Punch/Forming OperatorOEM$96.00 $20.86 58%$12.1019%$3.96 160% $59.08 $96.00US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm8 51-4032 Drilling and Boring MachineTool Setters, Operators, andTenders, Metal and PlasticSet up, operate, or tend drilling machines to drill,bore,ream, mill, or countersink metal or plastic work pieces.Smaller MachiningStations and/or with lessautomationDrilling/Boring Operator-OEM $112.19 $28.02 40%$11.2114%$3.92 160% $69.04 $112.19US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm9 51-4033 Grinding, Lapping, Polishing, and Buffing Machine ToolSetters, Operators, andTenders, Metal and PlasticsSet up, operate, or tend grinding and related toolsthatremove excess material or burrs from surfaces, sharpenedges or corners, or buff, hone, or polish metal orplastic work pieces.Smaller Grinding/HoningStations and/or with lessautomationGrinding/Polishing Operator-OEM $98.71 $22.87 50%$11.4416%$3.66 160% $60.74 $98.71US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm10 51-4034 Lather and Turning MachineTool Setters, Operators, andTenders, Metal and PlasticSet up, operate, or tend lathe and turning machinestoturn, bore, thread, form, or face metal or plasticmaterials, such as wire, rod, or bar stock.Smaller Turning Stationand/or with lessautomationLathe/Turning Operator-OEM $83.05 $21.73 37%$8.0410%$2.17 160% $51.11 $83.05US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm11 51-4035 Milling and Planing MachineSetters, Operators, andTenders, Metal and Plastic.Set up, operate, or tend milling or planing machinestomill, plane, shape, groove, or profile metal or plasticwork pieces.Milling Operations Milling/Planing Operator-OEM $71.22 $18.02 41%$7.3911%$1.98 160% $43.82 $71.22US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm12 51-4072 Molding, Core making, andCasting Machine Setters,Operators, and Tenders,Metal & PlasticSet up, operate, or tend metal or plastic molding,casting, or core making machines to mold or cast metalor thermoplastic parts or products.Molding and CastingOperatorsMold/Cast/Sinter Operator-OEM $77.92 $15.69 68%$10.6723%$3.61 160% $47.95 $77.92US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm13 51-4081 Multiple Machine ToolSetters, Operators, andTenders, Metal and Plastic.Set up, operate, or tend more than one type of cuttingor forming machine tool or robot.Smaller Machines and/orwith High Automation forInjection Molding orCastingWill not use, too general andoverlap with other categories.$87.55 $19.47 56%$10.9017%$3.31 160% $53.88 $87.55US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm14 51-4122 Welding, Soldering, andBrazing Machine Setters,Operators, and Tenders.Set up, operate, or tend welding, soldering, or brazingmachines or robots that weld, braze, solder, or heattreat metal products, components, or assemblies.Include workers who operate laser cutters or laser-beammachines.Various WeldingOperationsWelding/Soldering Operator-OEM $103.78 $27.34 35%$9.5711%$3.01 160% $63.87 $103.78US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htmFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.2, Page 3 of 4Author: Greg Kolwich(248) 373-6000 Ext 2411APPENDIX E.2 Labor Costing Database ExcerptAppendix E.2Printed:12/9/2009Production Year Start (Baseline)2008ActiveRate2008MeanHourlyWageIndirectLaborRateRatioILRR"%"IndirectLaborContribution$/HourMROLaborRateRatioMLRR"%"MRO LaborContribution$/HourFringeAllocation"%"FringeContribution$/HourTotalLaborRate$/HourInformation Source



# ItemSOCSCode(BLS)Direct Labor Title(BLS)Direct Labor Description (BLS)Typical ApplicationAssociationLabor Classification15 51-4191 Heat Treat EquipmentSetters, Operators, andTenders, Metal and PlasticSet up, operate, or tend heating equipment, such asheat-treating furnaces, flame-hardening machines,induction machines, soaking pits, or vacuum equipmentto temper, harden, anneal, or heat-treat metal or plasticobjects.Heat Treat Heat Treat Operator-OEM $137.35 $28.10 69%$19.3919%$5.34 160% $84.52 $137.35US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htm16 51-9122 Painters, TransportationEquipmentOperate or tend painting machines to paint surfaces oftransportation equipment, such as automobiles, buses,trucks, trains, boats, and airplanes. Include paintersinauto body repair facilities.Painting Painter Operator-OEM $105.77 $23.38 60%$14.0314%$3.27 160% $65.09 $105.77US Department of Labor, May 20007 National Industry-SpecificOccupational Employment and Wage EstimatesNAICS 336100 - Motor Vehicle Manufacturinghttp://www.bls.gov/oes/current/naics4_336100.htmIII. Miscellaneous1NA Not Applicable Category to be referenced when there is no impact onLabor associated with technology change.Not Applicable $0.00$0.00File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.2, Page 4 of 4Author: Greg Kolwich(248) 373-6000 Ext 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008A. THERMOPLASTIC PROCESSINGA1. Injection Molding ( General, Station Based, Potential for Material Considerations)1 Injection Molding Machines (1500-3000 Ton) 1 ChillerInject. Mold, LS $151.77 Harry Manvel-MitsubishiSales>harry@towerklean.com22 DryerRates calculated using acquired data and BurdenCalculator Template.33 Mold Temperature Control UnitWhere possible, rates were validated with T1/T2supplier data.44 Basic Material Handling Equipment551B1 Injection Molding Machines (800-1500 Ton) 1 ChillerIntake Manifolds, Inject. Mold, MLS $90.59 Same as above22 Dryer33 Temperature Control Unit44 Basic Material Handling Equipment551B1 Injection Molding Machines (400-800 Ton) 1 ChillerInject. Mold, LS $50.58 Same as above22 Dryer33 Mold Temperature Control Unit44 Basic Material Handling Equipment551B1 Injection Molding Machines (200-400 Ton) 1 ChillerTiming Chain Tensioner, Guides, Inject. Mold, SMS $28.80 Same as above22 Dryer33 Mold Temperature Control Unit44 Basic Material Handling Equipment551B1 Injection Molding Machines (55-150 Ton) 1 ChillerInject. Mold, SS $16.39 Same as above22 Dryer33 Mold Temperature Control Unit44 Basic Material Handling Equipment55C. CASTING PROCESSC1. Diecasting - Aluminum (General, Station Based )1 Cold Chamber Die Casting Machine (2600-3800 Ton) 1 Melting EquipmentEngine Blocks, Bed Plates, etc Diecast, LS, HC, w. Inserts $318.10 Die casting equipment source: Buhler PrinceMark.Los@Buhlerprince.com22Automation for applying mold release agents, removingcast parts, etc.Rates calculated using acquired data and BurdenCalculator Template.33 Die Cast Mold Temperature Control UnitWhen possible, rates were validated with T1/T2supplier data.44Robotic equipment for loading inserts into the tool.551 Cold Chamber Die Casting Machine (2600-3800 Ton) 1 Melting EquipmentDiecast, LS $301.91 Same as above22Automation for applying mold release agents, removingcast parts, etc.Diecast, LS, HC $301.9133 Die Cast Mold Temperature Control Unit44551 Cold Chamber Die Casting Machine (1800-2600 Ton) 1 Melting EquipmentDiecast, MLS $247.89 Same as above22Automation for applying mold release agents, removingcast parts, etc.Diecast, MHC $247.8933 Die Cast Mold Temperature Control Unit44551B1 Cold Chamber Die Casting Machine (1000-1800 Ton) 1 Melting EquipmentDiecast, MS $197.05 Same as above22Automation for applying mold release agents, removingcast parts, etc.$197.0533 Die Cast Mold Temperature Control Unit44551 Cold Chamber Die Casting Machine (500-1000 Ton) 1 Melting EquipmentDiecast, SMS $116.73 Same as above22Automation for applying mold release agents, removingcast parts, etc.Diecast, LMC $116.7333 Die Cast Mold Temperature Control Unit457A1.5 Injection Molding, Small Size and/orLow ComplexityA1.1 Injection Molding, Large Size and/orHigh ComplexityInjection Molding, Medium-Large Sizeand/or Moderate-High ComplexityAluminum Diecasting, Small-MediumSize and/or Low-Moderate ComplexityBurden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentAluminum Diecasting, Medium Sizeand/or Moderate Complexity.Injection Molding, Medium Size and/orModerate ComplexityInjection Molding, Small-Medium Sizeand/or Low-Moderate ComplexityAluminum Diecasting, Medium-LargeSize and/or Moderate-HighComplexity.Cat. Item Burden TitleA1.2A1.4A1.3C1.3C1.5C1.1 Aluminum Diecasting, Large,Complex Components with InsertsC1.2 Aluminum Diecasting, Large Sizeand/or High Complexity.C1.4A. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 1 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.1B1 Cold Chamber Die Casting Machine (0-500 Ton) 1 Melting EquipmentDiecast, SS $70.80 Same as above22Automation for applying mold release agents, removingcast parts, etc.33 Die Cast Mold Temperature Control Unit4457E. Stamping & Forming ProcessesE1. Stamping & Forming, General, Station Based1 Vertical Stamping Press, Tonnage 2000-3000 1 Uncoiler& StraightenerStamp/Form, 2XLS $281.92 Pricing information from Emprotech andConfidential Business Information (CBI) source.22Rates calculated using acquired data and BurdenCalculator Template.33Where possible, rates were validated with T1/T2supplier data.44551B1 Vertical Stamping Press, Tonnage 1500-2000 1 Uncoiler& StraightenerStamp/Form, XLS $199.37 Same as above223344551B1 Vertical Stamping Press, Tonnage 1000-1500 1 Uncoiler& StraightenerStamp/Form, LS $141.76 Same as above22Stamp/Form, MLS, MHC $141.763344551B1 Vertical Stamping Press, Tonnage 800-1000 1 Uncoiler &StraightenerStamp/Form, MLS $106.69 Same as above22Stamp/Form, SMS, MHC $0.003344551B1 Vertical Stamping Press, Tonnage 600-800 1 Uncoiler &StraightenerStamp/Form, MS $83.80 Same as above223344551B1 Vertical Stamping Press, Tonnage 400-600 1 Uncoiler &StraightenerStamp/Form, SMS $60.65 Same as above22Stamp/Form, SMS, LMC $60.653344551B1 Vertical Stamping Press, Tonnage 200-400 1 Uncoiler &StraightenerStamp/Form, SS $42.91 Same as above223344551B1 Vertical Stamping Press, Tonnage 60-200 1 Uncoiler & StraightenerStamp/Form, XSS $24.60 Same as above223344551B1 Vertical Stamping Press, Tonnage 0-60 1 Uncoiler & StraightenerStamp/Form, Terminals $15.50 Same as above22334455E1.7E1.8E1.9E1.2Stamping & Forming, Small SizeStamping & Forming, Extra LargeSize,E1.1Aluminum Diecasting, Small Sizeand/or Low ComplexityC1.6E1.4 Stamping & Forming, Medium-LargeSizeStamping & Forming, Small-MediumSizeStamping & Forming, 2X Large SizeE1.3 Stamping & Forming, Large SizeStamping & Forming, TerminalsElectrical TerminalsE1.5 Stamping & Forming, Medium SizeStamping & Forming, Extra SmallSizeE1.6File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 2 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.G. MachiningG1.≤4 Axis, Manual Load, CNC Horizontal Machining Center (X,Y,Z and Rotation "B"), General, Station Based1 HS-7R - Pallet Size 2032X1016 mm, 10,000 lbCapacity (PC:1 Chip RemovalCNC Machining, LS, HC $68.33 Primary cost data acquired from HAAS website,http://www.haascnc.com/home.asp (10/09)2 Work piece Envelop (Ø2450 x 1000 mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, LS, HC,PREM.$73.45Pricing information was also acquired fromPrecision Machining Technology Show 04/09).3 Travel X,Y,Z (2134, 1676, 1524) & 360 Rotation 3Rates calculated using acquired data and BurdenCalculator Template.4 Dual Pallet Changer4Where possible, rates were validated with T1/T2supplier data.5 38 Tool, Tool changer 51B1 EC-630 - Pallet Size 630 mm square, 2645 lb Capacity1 Chip RemovalCNC Machining, MHC $54.19 Same as above2 Workpiece Envelop (Ø891 x 798mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, MHC,PREM.$58.253 Travel X,Y,Z (1016, 838, 889) & 360 Rotation 34 Dual Pallet Changer45 50 Tool, Tool changer 51B1 EC-550 - Pallet Size 550 mm square, 2205 lb Capacity1 Chip RemovalCNC Machining, MC $46.31 Same as above2 Workpiece Envelop (Ø778 x 798mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, MC, PREM. $49.783 Travel X,Y,Z (762, 864, 813) & 360 Rotation 34 Dual Pallet Changer45 40 Tool, Tool changer 51B$0.001 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity1 Chip RemovalCNC Machining, LMC $35.42 Same as above2 Workpiece Envelop (Ø500 x 762mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, LMC,PREM.$38.083 Travel X,Y,Z (508,508,508) & 360 Rotation 34 Dual Pallet Changer45 24 Tool, Tool changer 51B1 EC-300 - Pallet Size 300 mm square, 550 lb Capacity 1Chip RemovalCNC Machining, LC $31.33 Same as above2 Workpiece Envelop (Ø381 x 572mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, LC, PREM. $33.683 Travel X,Y,Z (508,457,356) & 360 Rotation 3 Hydraulic Clamping4 Dual Pallet Changer4 Tool Probing System5 24 Tool, Tool changer 5G2.5 Axis and/or Automatic LoadCNC Horizontal Machining Center (X,Y,Z and Rotation"B", Tilt "A"), General, Station Based1 HS-7R - Pallet Size 2032X1016 mm, 10,000 lbCapacity (PC:1 Chip RemovalCNC Machining, LS, HC,Automatic Load$91.21 Primary cost data acquired from HAAS website,http://www.haascnc.com/home.asp (10/09)2 Workpiece Envelop (Ø2450 x 1000 mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, LS, HC,Automatic Load, PREM.$98.05Pricing information was also acquired fromPrecision Machining Technology Show 04/09).3 Travel X,Y,Z (2134, 1676, 1524), Rotation & Tilt 3 Hydraulic ClampingRates calculated using acquired data and BurdenCalculator Template.4 Dual Pallet Changer4 Tool Probing SystemWhere possible, rates were validated with T1/T2supplier data.5 38 Tool, Tool changer 5 Robotic Part Load/Unload1B1 EC-630 - Pallet Size 630 mm square, 2645 lb Capacity1 Chip RemovalCNC Machining, MHC,Automatic Load$69.96 Same as above2 Workpiece Envelop (Ø891 x 798mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, MHC,Automatic Load, PREM.$75.213 Travel X,Y,Z (1016, 838, 889), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer4 Tool Probing System5 50 Tool, Tool changer 5 Robotic Part Load/Unload1B1 EC-550 - Pallet Size 550 mm square, 2205 lb Capacity1 Chip RemovalCNC Machining, MC,Automatic Load$59.86 Same as above2 Workpiece Envelop (Ø778 x 798mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, MC,Automatic Load, PREM.$64.353 Travel X,Y,Z (762, 864, 813), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer4 Tool Probing System5 40 Tool, Tool changer 5 Robotic Part Load/UnloadG2.1Rear Covers - Block, Main Bearing CapBraceG1.5 CNC Machining, Small Size and/orLow Complexity(7.5% Premium paid for machiningaggressive materials)G2.2 5 Axis and/or Auto Load, CNCMachining, Auto Load, Medium-LargeSize and/or Moderate-HighComplexity.(7.5% Premium paid for machiningaggressive materials)5 Axis and/or Auto Load, CNCMachining, Large Size and/or HighComplexity(7.5% Premium paid for machiningaggressive materials, i.e.,Hypereutectic Aluminums)G1.4G1.1 CNC Machining, Large Size and/orHigh Complexity(7.5% Premium paid for machiningaggressive materials, i.e.,Hypereutectic Aluminums)Supplier Machining of large complexcastings, e.g. Engine BlocksExhaust Manifolds, Cylinder Head Covers,Front CoverG1.2 CNC Machining, Medium-Large Sizeand/or Moderate-High Complexity.(7.5% Premium paid for machiningaggressive materials)G2.3 5 Axis and/or Auto Load, 5 Axis CNCMachining, Auto Load, Medium Sizeand/or Moderate Complexity(7.5% Premium paid for machiningaggressive materials)G1.3 CNC Machining, Medium Size and/orModerate Complexity(7.5% Premium paid for machiningaggressive materials)CNC Machining, Small-Medium Sizeand/or Low-Moderate Complexity.(7.5% Premium paid for machiningaggressive materials)File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 3 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.1B1 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity1 Chip RemovalCNC Machining, LMC,Automatic Load$43.09 Same as above2 Workpiece Envelop (Ø500 x 762mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, LMC,Automatic Load, PREM.$46.323 Travel X,Y,Z (508,508,508), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer4 Tool Probing System5 24 Tool, Tool changer 5 Robotic Part Load/Unload1B1 EC-300 - Pallet Size 300 mm square, 550 lb Capacity 1Chip RemovalCNC Machining, LC,Automatic Load$37.95 Same as above2 Workpiece Envelop (Ø381 x 572mm) 2 Self-contained Coolant Delivery & FiltrationCNC Machining, LC,Automatic Load, PREM.$40.803 Travel X,Y,Z (508,457,356), Rotation & Tilt 3 Hydraulic Clamping4 Dual Pallet Changer4 Tool Probing System5 24 Tool, Tool changer 5 Robotic Part Load/UnloadG3.CNC Rotary or Linear Transfer Machining Centers,Option #1 -> Stationary Part, Option #2 - Part Indexing Stations, Option #3 - Part Turning Stations,General, Station Based1 Hydromat Trunnion V8 or V12 Type Equipment 1Small Casting Applications, Forgings,Irregular Bar Stock Components, etc.Rot./Lin. Trans. MachiningLine, SP$125.00 T1/T2 supplier data.2 Max 12 Stations2Rot./Lin. Trans. MachiningLine, SP, PREM.$181.253 12 Max Horizontal & 6 Max Vertical Tooling Spindle 3CNC Milling, LMC $125.004 Automated Part Flipping 45 Part is stationary fixtured/chucked, thus no indexing.5Custom application, fittings for brake tubes,oil lines etcCNC Milling, SMS, LC $100.006(Base Machine Cost 6 or less Stations, +5% Station)671 Hydromat Index Chuck Machine V12 or V16 TypeEquipment1Small Casting Applications, Forgings,Irregular Bar Stock Components, etc.Rot./Lin. Trans. MachiningLine, IP$175.00 T1/T2 supplier data.2 Max 16 Stations2Rot./Lin. Trans. MachiningLine, IP, PREM.$280.003 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)6771 Hydromat AT Advanced Technology Type Equipment 1Rot./Lin. Trans. MachiningLine, TP$250.00 T1/T2 supplier data.2 Max 10 Stations2Rot./Lin. Trans. MachiningLine, TP, PREM.$362.503 Horizontal & Vertical Tooling Spindle 3CNC Milling, LS, HC $250.004 Automated Part Flipping 45 Part Turning Capabilities @ each machining station. 56(Base Machine Cost 6 or less Stations, +5% Station)677G4. 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 HighComplexity Machining Center (i.e. 4 Axis). AddNumber of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.1Dedicated Machining Center -Single Station, HC, Base$68.33 Surrogate rate to 4 Axis CNC machining, largesize.2Total Value of Equipment: $400-500K23 Stations could be linked with additional machiningand/or other assembly stations.344.551B1 Rate based on $/Hour for a average station in a HighComplexity Machining Center (i.e. 4 Axis). AddNumber of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.1Dedicated Machining Center -Single Station, MHC, Base$54.19 Surrogate rate to 4 Axis CNC machining, medium-large size.2Total Value of Equipment: $300K-$400K23 Stations could be linked with additional machiningand/or other assembly stations.34455G4.1 Tier 1/2 Dedicated Machining Station,Large Size and/or High ComplexityG3.2G4.2 Tier 1/2 Dedicated Machining Station,Medium-Large Size and/or ModerateHigh ComplexityG2.5G3.3G3.1G2.4 5 Axis and/or Auto Load, CNCMachining, Small-Medium Size and/orLow-Moderate Complexity.(7.5% Premium paid for machiningaggressive materials)Automated Rotary or Linear Semidedicated transfer machines.Partstationary fixtured/chucked(7.5% Premium paid for machiningaggressive materials)Automated Rotary or Linear Semidedicated transfer machines.PartIndexing capability @ eachmachining station.(7.5% Premium paid for machiningaggressive materials)Automated Rotary or Linear Semidedicated transfer machines.PartTurning or Indexing capability @each machining station.(7.5% Premium paid for machiningaggressive materials)Small Casting Applications, Forgings,Irregular Bar Stock Components, etc.(Pistons)5 Axis and/or Auto Load, CNCMachining, Small Size and/or LowComplexity(7.5% Premium paid for machiningaggressive materials)File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 4 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.1B1 Rate based on $/Hour for a average station in a HighComplexity Machining Center (i.e. 4 Axis). AddNumber of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.1Dedicated Machining Center -Single Station, MC, Base$46.31 Surrogate rate to 4 Axis CNC machining, mediumsize.2Total Value of Equipment: $200K-300K23 Stations could be linked with additional machiningand/or other assembly stations.344551B1 Rate based on $/Hour for a average station in a HighComplexity Machining Center (i.e. 4 Axis). AddNumber of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.1Dedicated Machining Center -Single Station, LMC, Base$35.42 Surrogate rate to 4 Axis CNC machining, smallmedium size.2Total Value of Equipment: $100K-200K23 Stations could be linked with additional machiningand/or other assembly stations.344551B1 Rate based on $/Hour for a average station in a HighComplexity Machining Center (i.e. 4 Axis). AddNumber of stations in Manufacturing Assumption -Quote Summary Worksheet to calculate Burden Rate.1Dedicated Machining Center -Single Station, LC, Base$31.33 Surrogate rate to 4 Axis CNC machining, smallsize.2Total Value of Equipment: $0-$100K23 Stations could be linked with additional machining 34455G5. Machining, Component Specific, Line Base Rate per Primary Equipment Count1Average cost per primary equipment using in machiningprocess of Camshaft (e.g. establishing camshaftdatum's, turning journals and grinding lobes)1Camshaft MachiningEquipment$54.69Calculated 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) * 1.70 Factor (Ratio of primary tosecondary support equipment costs for cylinderhead line)223344551BH. CNC TurningH1. CNC Turning, Auto Bar Feed (BF), Dual Axis (DA)Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over baseassumptions.1 SL-40BB, Bar Capacity=Ø178mm 1Lathe Work Gauging ProbeCNC Turning, MLS, BF, DA $33.30Primary cost data acquired from HAAS website,http://www.haascnc.com/home.asp (10/09)2Max Cutting Diameter = Ø648mm, Max Cutting Length=1118 mm2Parts Catcher SystemPricing information was also acquired fromPrecision Machining Technology Show 04/09).3 12 Station Turret, Bolt on Tooling 3Tool Presetter SystemRates calculated using acquired data and BurdenCalculator Template.4 Automatic Bar Feeder 4Chip Auger with Mobile Chip LiftWhere possible, rates were validated with T1/T2supplier data.55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-30BB, Bar Capacity=Ø102mm 1Lathe Work Gauging ProbeCNC Turning, MS, BF, DA $27.50 Same as above2Max Cutting Diameter = Ø432mm, Max Cutting Length=864mm2Parts Catcher System3 12 Station Turret, Bolt on Tooling 3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-20BB, Bar Capacity=Ø64mm 1Lathe Work Gauging ProbeCNC Turning, SMS, BF, DA $23.14Same as above2Max Cutting Diameter = Ø262mm, Max Cutting Length=508mm2Parts Catcher System3 12 Station Turret, Bolt on Tooling 3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterG4.3 Tier 1/2 Dedicated Machining Station,Medium Size and/or ModerateComplexityConnecting Rods, Head Riser & Gate Cutoff and DebarringG4.5 Tier 1/2 Dedicated Machining Station,Small Size and/or Low ComplexityAverage Cost per Hour per Piece ofprimary Camshaft MachiningEquipmentCamshaftsG4.4 Tier 1/2 Dedicated Machining Station,Small-Medium Size and/or LowModerate ComplexityCalculated using( H.7.3) CNC Turning, Auto Load,Machining in "C","X", "Y" and "Z" Axis Only, AutomatedUnload, Small-Medium Size Parts ($32.17/Hour) * 1.70Factor (Ratio of primary to secondary supportequipment costs for cylinder head line)G5.1H1.1CNC Turning, Bar Fed, Machining in"C" and "Z" Axis Only, Medium-LargeSize PartsH1.2CNC Turning, Bar Fed, Machining in"C" and "Z" Axis Only, Medium SizePartsH1.3CNC Turning, Bar Fed, Machining in"C" and "Z" Axis Only, Small-MediumSize PartsFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 5 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.1 SL-10BB, Bar Capacity=Ø51mm 1Lathe Work Gauging ProbeCNC Turning, SS, BF, DA $20.90 Same as above2Max Cutting Diameter = Ø279mm, Max Cutting Length=356mm2Parts Catcher SystemCNC Turning, LC $20.903 12 Station Turret, Bolt on Tooling 3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterH2.1 SL-40BB, Bar Capacity=Ø178mm 1Lathe Work Gauging ProbeCNC Turning, MLS, BF, QA $52.75Primary cost data acquired from HAAS website,http://www.haascnc.com/home.asp (10/09)2Max Cutting Diameter = Ø648mm, Max Cutting Length=1118 mm2Automated part unloadPricing information was also acquired fromPrecision Machining Technology Show 04/09).312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter SystemRates calculated using acquired data and BurdenCalculator Template.4 Automatic Bar Feeder 4Chip Auger with Mobile Chip LiftWhere possible, rates were validated with T1/T2supplier data.55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-30BB, Bar Capacity=Ø102mm 1Lathe Work Gauging ProbeCNC Turning, MS, BF, QA $43.29 Same as above2Max Cutting Diameter = Ø432mm, Max Cutting Length=864mm2Automated part unload312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-20BB, Bar Capacity=Ø64mm 1Lathe Work Gauging ProbeCNC Turning, SMS, BF, QA $34.77 Same as above2Max Cutting Diameter = Ø262mm, Max Cutting Length=508mm2Automated part unload312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-10BB, Bar Capacity=Ø51mm 1Lathe Work Gauging ProbeCNC Turning, SS, BF, QA $30.84 Same as above2Max Cutting Diameter = Ø279mm, Max Cutting Length=356mm2Automated part unload.CNC Turning, MC $30.84312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter SystemCNC Turning, HC No Longer Valid4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterH3.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.1THEO-TL-35BB, Bar Capacity=Ø178mm1Lathe Work Gauging ProbeDS-CNC Turning, MLS, BF,DA$37.91Primary cost data acquired from HAAS website,http://www.haascnc.com/home.asp (10/09)2Max Cutting Diameter = Ø648mm, Max Cutting Length=1118 mm2Parts Catcher SystemPricing information was also acquired fromPrecision Machining Technology Show 04/09).3 12 Station Turret, Bolt on Tooling 3Tool Presetter SystemRates calculated using acquired data and BurdenCalculator Template.4 Automatic Bar Feeder 4Chip Auger with Mobile Chip LiftWhere possible, rates were validated with T1/T2supplier data.55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 TL-25 BB, Bar Capacity=Ø102mm 1Lathe Work Gauging ProbeDS-CNC Turning, MS, BF, DA $32.11 Same as above2Max Cutting Diameter = Ø406mm, Max Cutting Length=864mm2Parts Catcher System3 12 Station Turret, Bolt on Tooling 3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 TL-15BB, Bar Capacity=Ø64mm 1Lathe Work Gauging ProbeDS-CNC Turning, SMS, BF,DA$28.18 Same as above2Max Cutting Diameter = Ø208mm, Max Cutting Length=445mm2Parts Catcher System3 12 Station Turret, Bolt on Tooling 3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterH3.3Double Sided Part, CNC Turning, BarFed, Machining in "C" and "Z" AxisOnly, Small-Medium Size PartsH3.2Double Sided Part, CNC Turning, BarFed, Machining in "C" and "Z" AxisOnly, Medium Size PartsH3.1Double Sided Part, CNC Turning, BarFed, Machining in "C" and "Z" AxisOnly, Medium-Large Size PartsH1.4CNC Turning, Bar Fed, Machining in"C" and "Z" Axis Only, Small SizePartsH2.1CNC Turning, Bar Fed, Machining in"C" ,"X", "Y" and "Z" Axis Only,Automated Unload, Medium-LargeSize PartsCNC Turning, Auto Bar Feed (BF), Quad Axis (QA) Machining ("C" , "X", "Y" and "Z" Axis), Automated Unload, General, Station Based withmultiplier for added complexity over base assumptions.H2.3CNC Turning, Bar Fed, Machining in"C","X", "Y" and "Z" Axis Only,Automated Unload, Small-MediumSize PartsH2.2CNC Turning, Bar Fed, Machining in"C" ,"X", "Y"and "Z" Axis Only,Automated Unload, Medium SizePartsH2.4CNC Turning, Bar Fed, Machining in"C","X", "Y" and "Z" Axis Only,Automated Unload, Small Size PartsFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 6 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.1THEO-TL-05BB, Bar Capacity=Ø51mm1Lathe Work Gauging ProbeDS-CNC Turning, SS, BF, DA $25.94 Same as above2Max Cutting Diameter = Ø279mm, Max Cutting Length=356mm2Parts Catcher SystemS-CNC Turning, LC $25.943 12 Station Turret, Bolt on Tooling 3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterH4.1THEO-TL-35BB, Bar Capacity=Ø178mm1Lathe Work Gauging ProbeDS-CNC Turning, MLS, BF,QA$56.00Primary cost data acquired from HAAS website,http://www.haascnc.com/home.asp (10/09)2Max Cutting Diameter = Ø648mm, Max Cutting Length=1118 mm2Automated part unloadPricing information was also acquired fromPrecision Machining Technology Show 04/09).312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter SystemRates calculated using acquired data and BurdenCalculator Template.4 Automatic Bar Feeder 4Chip Auger with Mobile Chip LiftWhere possible, rates were validated with T1/T2supplier data.55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 TL-25 BB, Bar Capacity=Ø102mm 1Lathe Work Gauging ProbeDS-CNC Turning, MS, BF, QA $46.54 Same as above2Max Cutting Diameter = Ø406mm, Max Cutting Length=864mm2Automated part unload312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift5 Transfer Time to Sub-spindle 8 Seconds 5High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 TL-15BB, Bar Capacity=Ø64mm 1Lathe Work Gauging ProbeDS-CNC Turning, SMS, BF,QA$42.28 Same as above2Max Cutting Diameter = Ø208mm, Max Cutting Length=445mm2Automated part unload312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift5 Transfer Time to Sub-spindle 8 Seconds 5High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1THEO-TL-05BB, Bar Capacity=Ø51mm1Lathe Work Gauging ProbeDS-CNC Turning, SS, BF, QA $38.35 Same as above2Max Cutting Diameter = Ø279mm, Max Cutting Length=356mm2Automated part unload.S-CNC Turning, MC $38.35312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter SystemS-CNC Turning, HC No Longer Valid4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterH5.1 Hydromat Rotary Transfer Machine - Max 16 Station 1MS-16Max, CNC Turning,SMS, BF, QA$240.00 Estimated based equipment investment andsurrogate equipment overhead rates..2 Bar Size = Ø44 and Length 150 mm 2RTM Turning, HC, PP, Base $240.003 Up to 16 Horizontal & 8 Vertical Tooling Spindle 34 Automated Part Flipping 45(Base Machine Cost 12 Stations, +10% Station)566771 Hydromat Rotary Transfer Machine - Max 12 Station 1MS-12Max, CNC Turning,SMS, BF, QA$180.00 Estimated based equipment investment andsurrogate equipment overhead rates..2 Bar Size = Ø25 and Length 100 mm 2RTM Turning, MC, PP, Base $180.003 Up to 12 Horizontal & 6 Vertical Tooling Spindle 34 Automated Part Flipping 45(Base Machine Cost 8 Stations, +10% Station)56677H3.4Double Sided Part, CNC Turning, BarFed, Machining in "C" and "Z" AxisOnly, Small Size PartsH5.2 Multi Station -12, CNC Turning, AutoBar Fed, Machining in "C" ,"X", "Y"and "Z" Axis Only, Double Sided,Automated Unload, Small-MediumSize PartsH5.1 Multi Station -16, CNC Turning, AutoBar Fed, Machining in "C" ,"X", "Y"and "Z" Axis Only, Double Sided,Automated Unload, Small-MediumSize PartsDouble 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 complexityover base assumptions.H4.1Double Sided Part, CNC Turning, BarFed, Machining in "C" ,"X", "Y" and"Z" Axis Only, Automated Unload,Medium-Large Size PartsH4.2Double Sided Part, CNC Turning, BarFed, Machining in "C" ,"X", "Y"and "Z"Axis Only, Automated Unload,Medium Size PartsH4.3Double Sided Part, CNC Turning, BarFed, 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, AutomatedUnload, General, Station Based with multiplier foradded complexity over base assumptions.H4.4Double Sided Part CNC Turning, BarFed, Machining in "C","X", "Y" and "Z"Axis Only, Automated Unload, SmallSize PartsFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 7 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.1 Hydromat Inline Standard 8 - Max 8 Stations 1$0.002 Bar Size = Ø25 and Length 550 mm 23 Bar Stock or Blanks3445566771THEO-ZPS 842, 8 Station Turning Machine1Lathe Work Gauging ProbeMS-8Max, CNC Turning, SMS,BF, QA$213.49Primary pricing information was also acquiredfrom Precision Machining Technology Show04/09).2 Bar Size = Ø42 and Length 125 mm 2Automated part unloadSecondary cost data came from HAAS website,http://www.haascnc.com/home.asp (10/09)316 Station Turret: Average (8 Fixed, 4 Axial Live Toolsand 4 Radial Live Tools)3Tool Presetter SystemRates calculated using acquired data and BurdenCalculator Template.4 Automatic Bar Feeder 4Chip Auger with Mobile Chip LiftWhere possible, rates were validated with T1/T2supplier data.55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1THEO-ZPS 642, 6 Station Turning Machine1Lathe Work Gauging ProbeMS-6Max, CNC Turning, SMS,BF, QA$161.86 Same as above2 Bar Size = Ø42 and Length 125 mm 2Automated part unload.312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Tool Presetter System4 Automatic Bar Feeder 4Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 1000 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterH6.1 SL-40BB, Chuck Capacity=Ø178mm 1Lathe Work Gauging ProbeCNC Turning, MLS, ML, DA $31.74Primary cost data came from HAAS website,http://www.haascnc.com/home.asp (10/09)2Max Cutting Diameter = Ø648mm, Max Cutting Length=1118 mm2Parts Catcher SystemPricing information was also acquired fromPrecision Machining Technology Show 04/09).3 12 Station Turret, Bolt on Tooling 3Tool Presetter SystemRates calculated using acquired data and BurdenCalculator Template.44Chip Auger with Mobile Chip LiftWhere possible, rates were validated with T1/T2supplier data.55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-30BB, Chuck Capacity=Ø102mm 1Lathe Work Gauging ProbeCNC Turning, ML, ML, DA $25.79 Same as above2Max Cutting Diameter = Ø432mm, Max Cutting Length=864mm2Parts Catcher System3 12 Station Turret, Bolt on Tooling 3Tool Presetter System44Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-20BB, Chuck Capacity=Ø64mm 1Lathe Work Gauging ProbeCNC Turning, SMS, ML, DA $21.43 Same as above2Max Cutting Diameter = Ø262mm, Max Cutting Length=508mm2Parts Catcher System3 12 Station Turret, Bolt on Tooling 3Tool Presetter System44Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filter1 SL-10BB, Chuck Capacity=Ø51mm 1Lathe Work Gauging ProbeCNC Turning, SS, ML, DA $19.15 Same as above2Max Cutting Diameter = Ø279mm, Max Cutting Length=356mm2Parts Catcher System3 12 Station Turret, Bolt on Tooling 3Tool Presetter System44Chip Auger with Mobile Chip Lift55High-Pressure Coolant, 300 psi (21 bar)66Auxiliary Coolant Filter System, 25-micron filterOdd Form Part, CNC Turning, Manual Load (ML), Axis(DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity overbase assumptions.Category for odd form components, e.g.pre-machine bar stock, forged parts, diecastH6.4CNC Turning, Manual Load,Machining in "C" and "Z" Axis Only,Small Size PartsH6.3CNC Turning, Manual Load,Machining in "C" and "Z" Axis Only,Small-Medium Size PartsH6.2CNC Turning, Manual Load,Machining in "C" and "Z" Axis Only,Medium Size PartsH6.1CNC Turning, Manual Load,Machining in "C" and "Z" Axis Only,Medium-Large Size PartsH5.3Multi Station -8,Long Part,CNCTurning, Auto Bar Fed, Machining in"C" ,"X", "Y" and "Z" Axis Only,Double Sided, Automated Unload,Small-Medium Size PartsH5.4Multi Station -8, CNC Turning, AutoBar Fed, Machining in "C" ,"X", "Y"and "Z" Axis Only, Double Sided,Automated Unload, Small-MediumSize PartsH5.5Multi Station-6, CNC Turning, AutoBar Fed, Machining in "C" ,"X", "Y"and "Z" Axis Only, Double Sided,Automated Unload, Small-MediumSize PartsFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 8 of 9Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.3 Manufacturing Overhead Costing Database ExcerptAppendix E.3Printed:12/9/2009Information SourceActive Rate2008Burden ClassificationProduct ExamplesPrimary Processing Equipment Secondary Process EquipmentCat. Item Burden TitleA. ThermoplasticB. ThermosetC. CastingD. ForgingH. TurningG. MachiningJ. GrindingF. Powder MetalE. Stamping & FormingM. PlatingR. OEM AssemblyS.T.Q. OEM MachiningN. WashingL. Heat TreatP. T1/T2/T3 Ass'yK. BalancingU.V.W.X.Y. MiscellaneousZ.H7.1 SL-40BB, Chuck Capacity=Ø178mm 1Lathe Work Gauging ProbeCNC Turning, MLS, AL, QA $48.72Primary cost data came from HAAS website,http://www.haascnc.com/home.asp (10/09)2Max Cutting Diameter = Ø648mm, Max Cutting Length=1118 mm2Tool Presetter SystemPricing information was also acquired fromPrecision Machining Technology Show 04/09).312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Chip Auger with Mobile Chip Lift$82.82Rates calculated using acquired data and BurdenCalculator Template.4 Automatic Part Load & Unload System 4High-Pressure Coolant, 1000 psi (21 bar)Where possible, rates were validated with T1/T255Auxiliary Coolant Filter System, 25-micron filter661 SL-30BB, Chuck Capacity=Ø102mm 1Lathe Work Gauging ProbeCNC Turning, MS, AL, QA $39.48 Same as above2Max Cutting Diameter = Ø432mm, Max Cutting Length=864mm2Tool Presetter System312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Chip Auger with Mobile Chip Lift4 Automatic Part Load & Unload System 4High-Pressure Coolant, 1000 psi (21 bar)55Auxiliary Coolant Filter System, 25-micron filter661 SL-20BB, Chuck Capacity=Ø64mm 1Lathe Work Gauging ProbeCNC Turning, SMS, AL, QA $32.17 Same as above2Max Cutting Diameter = Ø262mm, Max Cutting Length=508mm2Tool Presetter System312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Chip Auger with Mobile Chip Lift4 Automatic Part Load & Unload System 4High-Pressure Coolant, 1000 psi (21 bar)55Auxiliary Coolant Filter System, 25-micron filter661 SL-10BB, Chuck Capacity=Ø51mm 1Lathe Work Gauging ProbeCNC Turning, SS, AL, QA $27.47 Same as above2Max Cutting Diameter = Ø279mm, Max Cutting Length=356mm2Tool Presetter System312 Station Turret: Average (6 Fixed, 3 Axial Live Toolsand 3 Radial Live Tools)3Chip Auger with Mobile Chip Lift4 Automatic Part Load & Unload System 4High-Pressure Coolant, 1000 psi (21 bar)55Auxiliary Coolant Filter System, 25-micron filter66Q. OEM MachiningQ1. OEM Machining, Component Specific, Line Based using Multiplier X number of pieces of primary equipment11CNC Machining, Crankshafts,OEM$67.122233445514 & 5 Axis CNC Machines,or1 Automation (Gantry robot w/automation) per CNCmachining operationCNC Machining, CylinderBlock, OEM$81.112Custom Machining Centers,or2 Main Line automation (gantry robot & automation) peroperation3In-line Washers,or3 Coolant System, Mist Collection, Process Water &Waste, Misc. Department Equipment4 In-Line Inspection & Gauging 4 Production Floor CMM5514 & 5 Axis CNC Machines,or1 Automation (Gantry robot w/automation) per CNCmachining operationCNC Machining, CylinderHead, OEM$79.052Custom Machining Centers,or2 Main Line automation (gantry robot & automation) peroperation3Head Assembly Equipment (on Machining line),or3 Coolant System, Mist Collection, Process Water &Waste, Misc. Department Equipment4In-line Washers,or4 Production Floor CMM5 In-Line Inspection & Gauging 5H7.4CNC Turning, Auto Load, Machiningin "C","X", "Y" and "Z" Axis Only,Automated Unload, Small Size PartsH7.3CNC Turning, Auto Load, Machiningin "C","X", "Y" and "Z" Axis Only,Automated Unload, Small-MediumSize PartsH7.2CNC Turning, Auto Load, Machiningin "C" ,"X", "Y"and "Z" Axis Only,Automated Unload, Medium SizePartsH7.1CNC Turning, Auto Load, Machiningin "C" ,"X", "Y" and "Z" Axis Only,Automated Unload, Medium-LargeSize PartsOdd 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 oddform components, e.g. pre-machine bar stock, forQ1.1 Crankshaft MachiningCalculated using( H.7.3) CNC Turning, Auto Load,Machining in "C","X", "Y" and "Z" Axis Only, AutomatedUnload, Medium Size Parts ($39.48/Hour) * 1.70 Factor(Ratio of primary to secondary support equipment costsfor cylinder head line)Q1.2 Cylinder Block Machining Line(Average cost per primary piece ofmanufacturing equipment on acylinder block machining line)Q1.3 Cylinder Head Machining Line(Average cost per primary piece ofmanufacturing equipment on acylinder head machining line)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 tosecondary support equipment costs for cylinderhead line)Average cost per primary equipment using in machiningprocess of crankshaft (e.g. Machining Center forDatums, Turn-Turn broach, OD Mill, Multi-wheel MainGrinder, Pin Grinder etc)Average rate per primary piece of equipment iscalculated by dividing the total estimated facilitycosts (primary and ancillary tracked separately),by the total primary equipment quantity, toestablish an average primary and ancillaryinvestment cost per unit of primary equipment.These average costs, along with supporting costand specification data from surrogate equipment,are fed into the burden calculator to establish amanufacturing overhead rate.Average rate per primary piece of equipment iscalculated by dividing the total estimated facilitycosts (primary and ancillary tracked separately),by the total primary equipment quantity, toestablish an average primary and ancillaryinvestment cost per unit of primary equipment.These average costs, along with supporting costand specification data from surrogate equipment,are fed into the burden calculator to establish amanufacturing overhead rate.File:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.3, Page 9 of 9Form 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 Si ze 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, 5.0E 5, 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 Appr oval Process PPAP) ( one time expense, value default 5% )

Process Support Equipment Sub-total Including Freig ht, Installation, Set-up and Run-off. (C.5+C.6+C.7+ C.8+C.9)

Annual Financing Expense for Process Support Equipm ent Sub-total (C.10) Installation (one time expense)

Process Support Equipment Design (Customized equipm ent/machinery or highly complex integration of comm odity

based equipment)

Process Support Equipment Cost (C.1+C.2) Process Support Equipment Build Annual Financing Expense for Primary Process Equipm ent 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 Appr oval Process PPAP) ( one time expense, value default 5% )

Spare Parts-Maintenance & Repair, includes perishab le goods ( default 3%/year ) Primary Process Equipment Sub-total Including Freig ht, 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 (Re quired 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 Cos ts per Year General Material Handling Equipment (e.g. Tow-Moto rs, Cranes, Fork Lifts)

Plant Cleaning Equipment Spare Parts-Maintenance & Repair, includes perishab le 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 equipm ent/machinery or highly complex integration of comm odity

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 (2002-2 007):

>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 Si ze 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, 5.0E 5, 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 (2002-2 007):

>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 Ov erhead/Year 

# 750,000

1,000,000

2,000,000 Estimated Facility Square Footage



# 150,000

250,000

500,000 Plant Salary Contribution to Manufacturing Overhea d (Note, does not include, direct, indirect or Main tenance,

Repair or Other Labor) Supporting Process

Equipment Utility Usage Total Process Support Equipment Floor Space Allocat ion:

( Equipment Foot Print + 3 ft each side)

General Plant & Office Equipment/Hardware Floor Spa ce

Total utilities expense/hour for all Primary and Su pporting Process Equipment Primary Process Equipment Usage Total Facilities Costs per Year

Utilities for Primary Process Equipment, Process Su pport Equipment & General Plant and Office

Hardware/Equipment. Total Primary Processing Equipment Floor Space Allo cation

( Equipment Foot Print + 3 ft each side) Facilities Cost/Floor Space Includes (Cost/Square F oot) -> Primary Process Equipment, Process Support

Equipment, & General Plant Office Hardware/Equipmen t

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 Si ze 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, 5.0E 5, 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 (2002-2 007):

>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 g rouping (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 util ization

Total Hourly Rate base on defined efficiency and 10 0% utilization

Total Hourly Rate base on defined efficiency and ut ilization $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. 2411APPENDIX E.5 Mark-up Rate Database ExcerptAppendix E.5Printed:12/9/2009Production Year/Case Study2008End Item Scrape Average Annual Adjustment Factor (AAF)0.00%Selling, General, and Administrative (SG&A), Average Annual Adjustment Factor (AAF)0.00%Profit, Average Annual Adjustment Factor (AAF)0.00%TOPBOTTOMED&T/R&D, Average Annual Adjustment Factor (AAF)0.00%End ItemScrap,ActiveRateSG&A,ActiveRateProfit,ActiveRateED&T/R&D,ActiveRateEnd ItemScrapRate,BaselineSG&ARate,BaselineProfitRate,BaselineED&T/R&DRate,BaselineEndItemScrap,AAFSG&A,AAFProfit,AAFED&T/R&D,AAFEnd ItemScrapRate,AdjustedSG&ARate,AdjustedProfitRate,AdjustedED&T/R&DRate,AdjustedNotes2020 2008 2008 2008A. T2/T3 THERMOPLASTIC PROCESSING1 Large Size, High Complexity 1T2/T3 Inject. Mold, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Inject. Mold, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Inject. Mold, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%22334455B. T2/T3 THERMOSET PROCESSING1 Large Size, High Complexity 1T2/T3 Comp./Ext. Mold, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Comp./Ext. Mold, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Comp./Ext. Mold, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%22334455C. T2/T3 CASTING PROCESS1 Large Size, High Complexity 1T2/T3 Diecast, LSHC5.00%7.00%8.00%2.00%5.00% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%5.00%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Diecast, MSMC5.00%6.50%6.00%1.00%5.00% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%5.00%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Diecast, SSLC5.00%6.00%4.00%0.00%5.00% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%5.00%6.00%4.00%0.00%223344551 Large Size, High Complexity 1T2/T3 Sand Cast, LSHC5.00%7.00%8.00%2.00%5.00% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%5.00%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Sand Cast, MSMC5.00%6.50%6.00%1.00%5.00% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%5.00%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Sand Cast, SSLC5.00%6.00%4.00%0.00%5.00% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%5.00%6.00%4.00%0.00%22334455C3.3Sand Casting,(Gravity and Low Pressure Casting)(Cast Iron(s), Steel, Aluminum)C3.2Sand Casting,(Gravity and Low Pressure Casting)(Cast Iron(s), Steel, Aluminum)C3.1Sand Casting,(Gravity and Low Pressure Casting)(Cast Iron(s), Steel, Aluminum)C1.3Diecasting(Aluminum, Magnesium, Zinc)C1.2Diecasting(Aluminum, Magnesium, Zinc)C1.1Diecasting(Aluminum, Magnesium, Zinc)B1.3Compression and Extrusion Moldingof Thermosetting PolymersB1.2Compression and Extrusion Moldingof Thermosetting PolymersB1.1Compression and Extrusion Moldingof Thermosetting PolymersInjection MoldingItemSupplier/OEM Classification(Based On ManufacturingOverhead Categories)Injection MoldingOEM or SupplierClassificationA1.3Supplier/OEM Size &Complexity DescriptionCat.A1.1 Injection MoldingA1.2A. T2/T3 ThermoPlast.B. T2/T3 ThermosetC. T2/T3 CastingD. T2/T3 ForgingH. T2/T3 Heat TreatG. T2/T3 MachiningI. T2/T3 PlatingF. T2/T3 Powder MetalE. T2/T3 Stamp-FormL.P. OEM AssemblyQ.Z. MISCO.M.K. T2/T3 Misc.N. T1 AssemblyJ.T2/T3AssemblyFile: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.5, Page 1 of 5Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.5 Mark-up Rate Database ExcerptAppendix E.5Printed:12/9/2009Production Year/Case Study2008End Item Scrape Average Annual Adjustment Factor (AAF)0.00%Selling, General, and Administrative (SG&A), Average Annual Adjustment Factor (AAF)0.00%Profit, Average Annual Adjustment Factor (AAF)0.00%TOPBOTTOMED&T/R&D, Average Annual Adjustment Factor (AAF)0.00%End ItemScrap,ActiveRateSG&A,ActiveRateProfit,ActiveRateED&T/R&D,ActiveRateEnd ItemScrapRate,BaselineSG&ARate,BaselineProfitRate,BaselineED&T/R&DRate,BaselineEndItemScrap,AAFSG&A,AAFProfit,AAFED&T/R&D,AAFEnd ItemScrapRate,AdjustedSG&ARate,AdjustedProfitRate,AdjustedED&T/R&DRate,AdjustedNotes2020 2008 2008 2008ItemSupplier/OEM Classification(Based On ManufacturingOverhead Categories)OEM or SupplierClassificationSupplier/OEM Size &Complexity DescriptionCat.A. T2/T3 ThermoPlast.B. T2/T3 ThermosetC. T2/T3 CastingD. T2/T3 ForgingH. T2/T3 Heat TreatG. T2/T3 MachiningI. T2/T3 PlatingF. T2/T3 Powder MetalE. T2/T3 Stamp-FormL.P. OEM AssemblyQ.Z. MISCO.M.K. T2/T3 Misc.N. T1 AssemblyJ.T2/T3Assembly1 Large Size, High Complexity 1T2/T3 Invest. Cast, LSHC5.00%7.00%8.00%2.00%5.00% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%5.00%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Invest. Cast, MSMC5.00%6.50%6.00%1.00%5.00% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%5.00%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Invest. Cast, SSLC5.00%6.00%4.00%0.00%5.00% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%5.00%6.00%4.00%0.00%22334455D. T2/T3 FORGING PROCESS1 Large Size, High Complexity 1T2/T3 Forge, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Forge, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Forge, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%2233445511223344551 Large Size, High Complexity 1T2/T3 Cold Forge, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Cold Forge, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Cold Forge, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%22334455E. T2/T3 STAMPING & FORMING PROCESS1 Large Size, High Complexity 1T2/T3 Stamp/Form, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Stamp/Form, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Stamp/Form, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%22334455E1.3 Stamping & Forming,E1.1 Stamping & Forming,D2.3Cold Forgings, Cold Heading,Coining, Thread Rolling, etc.,D2.2D2.1Cold Forgings, Includes ColdBending, Cold Drawing, Extrusions,Etc.,Cold Forgings, Includes ColdBending, Cold Drawing, Extrusions,Etc.,D1.3D1.1 Impression/Close Die Forging,C4.3Investment Casting, Great forCasting High Temp, Complex partsin aluminum alloys, bronze alloys,magnesium alloys, cast iron,stainless steel and tool steel.D1.2 Impression/Close Die Forging,C4.1Investment Casting, Great forCasting High Temp, Complex partsin aluminum alloys, bronze alloys,magnesium alloys, cast iron,stainless steel and tool steel.C4.2Investment Casting, Great forCasting High Temp, Complex partsin 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 WA13E.5, Page 2 of 5Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.5 Mark-up Rate Database ExcerptAppendix E.5Printed:12/9/2009Production Year/Case Study2008End Item Scrape Average Annual Adjustment Factor (AAF)0.00%Selling, General, and Administrative (SG&A), Average Annual Adjustment Factor (AAF)0.00%Profit, Average Annual Adjustment Factor (AAF)0.00%TOPBOTTOMED&T/R&D, Average Annual Adjustment Factor (AAF)0.00%End ItemScrap,ActiveRateSG&A,ActiveRateProfit,ActiveRateED&T/R&D,ActiveRateEnd ItemScrapRate,BaselineSG&ARate,BaselineProfitRate,BaselineED&T/R&DRate,BaselineEndItemScrap,AAFSG&A,AAFProfit,AAFED&T/R&D,AAFEnd ItemScrapRate,AdjustedSG&ARate,AdjustedProfitRate,AdjustedED&T/R&DRate,AdjustedNotes2020 2008 2008 2008ItemSupplier/OEM Classification(Based On ManufacturingOverhead Categories)OEM or SupplierClassificationSupplier/OEM Size &Complexity DescriptionCat.A. T2/T3 ThermoPlast.B. T2/T3 ThermosetC. T2/T3 CastingD. T2/T3 ForgingH. T2/T3 Heat TreatG. T2/T3 MachiningI. T2/T3 PlatingF. T2/T3 Powder MetalE. T2/T3 Stamp-FormL.P. OEM AssemblyQ.Z. MISCO.M.K. T2/T3 Misc.N. T1 AssemblyJ.T2/T3AssemblyF. T2/T3 POWDER METAL PROCESS1 Large Size, High Complexity 1T2/T3 Powder Metal, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Powder Metal, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Powder Metal, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%223344551122334455G. T2/T3 MACHINING PROCESS1 Large Size, High Complexity 1T2/T3 CNC Milling, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 CNC Milling, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 CNC Milling, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%2233445511223344551 Large Size, High Complexity 1T2/T3 CNC Turning, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 CNC Turning, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 CNC Turning, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%223344551122334455H. T2/T3 HEAT TREATING PROCESS1 Large Size, High Complexity 1T2/T3 Heat Treat, LSHC0.70% 7.00% 8.00% 2.00%0.70% 7.00% 8.00% 2.00%0.00% 0.00% 0.00% 0.00% 0.70% 7.00% 8.00% 2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Heat Treat, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%22334455F1.1Powder Metal, StructuralComponentsF1.2Powder Metal, Structural & BearingComponents,F1.3Powder Metal, Structural & BearingComponents,G1.1CNC and Rotary & Linear TransferMachiningG1.2CNC and Rotary & Linear TransferMachiningG1.3CNC and Rotary & Linear TransferMachiningG2.2 CNC TurningG2.1 CNC TurningG2.3 CNC TurningH1.1H1.2Heat Treating,Heat Treating,File: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.5, Page 3 of 5Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.5 Mark-up Rate Database ExcerptAppendix E.5Printed:12/9/2009Production Year/Case Study2008End Item Scrape Average Annual Adjustment Factor (AAF)0.00%Selling, General, and Administrative (SG&A), Average Annual Adjustment Factor (AAF)0.00%Profit, Average Annual Adjustment Factor (AAF)0.00%TOPBOTTOMED&T/R&D, Average Annual Adjustment Factor (AAF)0.00%End ItemScrap,ActiveRateSG&A,ActiveRateProfit,ActiveRateED&T/R&D,ActiveRateEnd ItemScrapRate,BaselineSG&ARate,BaselineProfitRate,BaselineED&T/R&DRate,BaselineEndItemScrap,AAFSG&A,AAFProfit,AAFED&T/R&D,AAFEnd ItemScrapRate,AdjustedSG&ARate,AdjustedProfitRate,AdjustedED&T/R&DRate,AdjustedNotes2020 2008 2008 2008ItemSupplier/OEM Classification(Based On ManufacturingOverhead Categories)OEM or SupplierClassificationSupplier/OEM Size &Complexity DescriptionCat.A. T2/T3 ThermoPlast.B. T2/T3 ThermosetC. T2/T3 CastingD. T2/T3 ForgingH. T2/T3 Heat TreatG. T2/T3 MachiningI. T2/T3 PlatingF. T2/T3 Powder MetalE. T2/T3 Stamp-FormL.P. OEM AssemblyQ.Z. MISCO.M.K. T2/T3 Misc.N. T1 AssemblyJ.T2/T3Assembly1 Small Size, Low Complexity 1T2/T3 Heat Treat, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%22334455J. T2/T3 ASSEMBLY PROCESS1 Large Size, High Complexity 1T2/T3 Mech. Assembly, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Mech. Assembly, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Mech. Assembly, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%2233445511223344551 Large Size, High Complexity 1T2/T3 Elect. Assembly, LSHC0.70%7.00%8.00%2.00%0.70% 7.00% 8.00% 2.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%2.00%223344551 Medium Size, Moderate Complexity 1T2/T3 Elect. Assembly, MSMC0.50%6.50%6.00%1.00%0.50% 6.50% 6.00% 1.00%0.00%0.00%0.00%0.00%0.50%6.50%6.00%1.00%223344551 Small Size, Low Complexity 1T2/T3 Elect. Assembly, SSLC0.30%6.00%4.00%0.00%0.30% 6.00% 4.00% 0.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%0.00%22334455N. T1 Assembly11T1 System Assembly Complexity0.70%7.00%8.00%6.00%0.70% 7.00% 8.00% 6.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%6.00%2233445511T1 High Assembly Complexity0.70%7.00%8.00%4.00%0.70% 7.00% 8.00% 4.00%0.00%0.00%0.00%0.00%0.70%7.00%8.00%4.00%2233445511T1 Moderate Assembly Complexity0.50%6.50%6.00%2.50%0.50% 6.50% 6.00% 2.50%0.00%0.00%0.00%0.00%0.50%6.50%6.00%2.50%2233445511T1 Low Assembly Complexity0.30%6.00%4.00%1.00%0.30% 6.00% 4.00% 1.00%0.00%0.00%0.00%0.00%0.30%6.00%4.00%1.00%22334455N1.4T1 Low Complexity ComponentSupplierN1.3T1 Moderate Complexity ComponentSupplierJ1.2 General Mechanical AssemblyHeat Treating,H1.3J1.3 General Mechanical AssemblyJ1.1 General Mechanical AssemblyJ2.1 General Electrical AssemblyJ2.2 General Electrical AssemblyJ2.3 General Electrical AssemblyN1.1T1 Complete System/SystemSupplierN1.2T1 High Complexity ComponentSupplierFile: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.5, Page 4 of 5Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.5 Mark-up Rate Database ExcerptAppendix E.5Printed:12/9/2009Production Year/Case Study2008End Item Scrape Average Annual Adjustment Factor (AAF)0.00%Selling, General, and Administrative (SG&A), Average Annual Adjustment Factor (AAF)0.00%Profit, Average Annual Adjustment Factor (AAF)0.00%TOPBOTTOMED&T/R&D, Average Annual Adjustment Factor (AAF)0.00%End ItemScrap,ActiveRateSG&A,ActiveRateProfit,ActiveRateED&T/R&D,ActiveRateEnd ItemScrapRate,BaselineSG&ARate,BaselineProfitRate,BaselineED&T/R&DRate,BaselineEndItemScrap,AAFSG&A,AAFProfit,AAFED&T/R&D,AAFEnd ItemScrapRate,AdjustedSG&ARate,AdjustedProfitRate,AdjustedED&T/R&DRate,AdjustedNotes2020 2008 2008 2008ItemSupplier/OEM Classification(Based On ManufacturingOverhead Categories)OEM or SupplierClassificationSupplier/OEM Size &Complexity DescriptionCat.A. T2/T3 ThermoPlast.B. T2/T3 ThermosetC. T2/T3 CastingD. T2/T3 ForgingH. T2/T3 Heat TreatG. T2/T3 MachiningI. T2/T3 PlatingF. T2/T3 Powder MetalE. T2/T3 Stamp-FormL.P. OEM AssemblyQ.Z. MISCO.M.K. T2/T3 Misc.N. T1 AssemblyJ.T2/T3AssemblyP. OEM ASSEMBLY11OEM Body & White Assembly0.00%0.00%0.00%0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%2233445511OEM Engine Casting0.00%0.00%0.00%0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%2233445511OEM Engine Machining0.00%0.00%0.00%0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%2233445511OEM Engine Assembly0.00%0.00%0.00%0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%2233445511OEM Vehicle Assembly0.00%0.00%0.00%0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%2233445511OEM Transmission Assembly0.00%0.00%0.00%0.00%0.00% 0.00% 0.00% 0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%0.00%22334455Z. MISCELLANEOUS1Category to be referenced when there isno impact on Mark-up associated withtechnology change.1Not Applicable0.00% 0.00% 0.00% 0.00%0.00% 0.00% 0.00% 0.00%0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%2233445511T1 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% 0.00% 0.00% 0.00% 0.00% 0.00%22334455P1.4 Engine AssemblyP1.3Machining Major EngineComponentsP1.2 Casting Major Engine ComponentsP1.1Body & White Assembly - OEM,Includes Press Shop, Welding andPaintingP1.5 Vehicle Operations AssemblyZ1.1 Not ApplicableZ1.2T1 Assembly, Mark-up Captured @Bottom of quote sheet.P1.6 Transmission AssemblyFile: Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA13E.5, Page 5 of 5Form Author: G. Kolwich(248) 373-6000 Ext. 2411APPENDIX E.6 Packaging Costing Database ExcerptAppendix E.6"Inches""mm""Inches""mm"Length 53' 636 16154 570 144782. 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 2727Units Length WidthHeightorThicknessLength WidthHeightorThicknessAPrimary Packaging Containers and PalletsInches 48 45 34 44 41.5 27.5Other 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 278BRetunable Internal & Support DunnageInches 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 NAInchesmmCExpendable Internal DunnageInches 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 NAB3C3Reference SourceB4 Seat Belt, Tie-down StrapsEstimated cost per pallet forprimary packaging option A25 $100 Tier #1 CBI$5Dimension Notes: Associated PackagingLifeExpectancy"Years"Unit CostEstimateUsed with option A2 primarypackaging.5 $40$200$100$1 Tier #1 CBI - Mike S.$3 Tier #1 CBI - Mike S.C2 Cardboard Divider Pads, Generic AssumptionUsed with option A1 primarypackaging.0C1 Cardboard Tier PadsUsed with option A1 primarypackaging.0EstimateB2 0.10" ABS Vacuum Form Tier PadsUsed with option A3 or A4 primarypackaging.50.10" Corrugated Plastic Dividers, GenericAssumptionUsed with option A1 primarypackaging. This is an averageestimated cost independent ofnumber of cells.2.5 $20Tier #1 CBI - Mike S.Tier #1 CBI - Mike S.Tier #1 CBI - Mike S.Tier #1 CBI - Mike S.Tier #1 CBI - Mike S.Tier #1 CBI - Mike S.$75$751. Standard Lengths: (28', 32', 36', 40', 42', 43',45', 48',and 53' )ExteriorDimensionsInteriorDimensionsProjectTrailer SizeSelectionFreight Trailer Key Dimensions555A25Internal dunnage either expendableor returnable.Returnable vacuum formed tierpads.Stacked on base pallet, 6Totes/Layer, Max 7 LayersStacked on base pallet, 6Totes/Layer, Max 7 LayersStandard AIAG Container, 4 Door, Collapsible SideWallsMulti Use Rackable PalletStackable Totes (Flexcon)Stackable Totes (Generic)Interior DimensionsA11/4" HDPE Vacuum Form Tier PadsA3A5B1Exterior DimensionsOption Packaging DescriptionA4Freight Trailer Information Source: www.worldtraderef.com/WTR_site/Truck_Trailers/Guide_to_Truck_Trailers.aspFile:Final Report Costing Databases 120809.xlsEPA Contract: EP-C-07-069 WA1-3E.6, Page 1 of 1Form Author: G. Kolwich(248) 373-6000 Ext. 2411

# 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 workshe et 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 assemb ly 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 COSTAPPENDIX F.1 MAQS Worksheet Task Reference GuideEPA Contract: EP-C-07-069 WA1-3 F.1, Page 15 of16APPENDIX F.1 MAQS Worksheet Task Reference GuideEPA Contract: EP-C-07-069 WA1-3 F.1, Page 16 of16

# 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 1Appendix G.1 - Subsystem 03Crank Drive SubsystemCase Study #0101MAQS WorksheetsFile:Crank Drives 03, 032509.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-03, 1 of 7Crankshaft 0301Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03 (1of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Shaft - CrankPart Number:0301-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Shaft - Crank (Mini Cooper) 0301-N0101-011Considered for Weight DeltaOnly, Assume Fabrication andMachining times a washbetween Mini and ChryslerCrankshaftOEM MA-Steel-MnVS, Bar Not Applicable Not Applicable116 025.28$0.73 $0.00 $0.00 $18.45$0.00 $0.00$18.450.00% 0.00% 0.00% 0.00%0.00% $0.00 $18.45 $18.45Shaft - Crank ( Chrysler Gema) 0301-B0101-011"See Note Above" OEM MA-Steel-MnVS, Bar Not ApplicableNot Applicable116 0-39.81$0.73 $0.00 $0.00 -$29.06$0.00 $0.00-$29.060.00% 0.00% 0.00% 0.00%0.00% $0.00 -$29.06 -$29.06Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up-$10.61T1 or OEM Total Manufacturing Cost:-$10.61 $0.00 $0.00 -$10.61 $0.00 $0.00 $0.00 $0.00 $0.00 -$10.61T1 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 -$1.67Base Cost Impact to Vehicle:-$10.61 $0.00 $0.00 -$10.61 -$0.07 -$0.74 -$0.85 $0.00 -$1.67 -$12.27 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$12.27Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BTBD109,57447450,0001450,000PACKAGING CALCULATIONS:Assume No Impact to Packaging"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 2 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Con.Rod0303Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (2of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Rod Subassembly - ConnectingPart Number:0303-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Rod Subassembly - Connecting 0303-N0101-01-011Weight Cost Differential Only,Fabrication and Machining areequivalent between Mini &Chrysler Con. Rods.Mini-Cooper RodL/R = 138.5/(85.9/2) = 3.22S MA-Steel-C70S6, Bar Not Applicable Not Applicable450 00.964$0.70 $0.00 $0.00 $0.67$0.00 $0.00$0.670.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.67 $0.671B Rod Subassembly - Connecting 0303-N0101-011Install Bushing & Size S Not Applicable General Assembly Mech. Assembly, MC450 00.000$0.00 $35.51 $125.19$0.00 $0.00$0.28 $0.280.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.28 $0.282A Rod Subassembly - Connecting 0303-B0101-01&021Chrysler GEMA Rod WeightMA-Steel-C70S6, Bar Not Applicable Not Applicable450 0-0.979$0.70 $0.00 $0.00 -$0.69$0.00 $0.00-$0.690.00% 0.00% 0.00% 0.00%0.00% $0.00 -$0.69 -$0.692B Rod Subassembly - Connecting 0303-B0101-01&02-M1Additional Material Requiredto Equalize L/R RatioGEMA Prod. L/R = 2.96,R = 97/2 = 48.5 & L=143.75mmAssuming Mini L/R (3.22).Hold stroke constantL=3.22*48.5= 156.17mmTherefore rod length wouldincrease by 12.42mmMA-Steel-C70S6, Bar Not Applicable Not Applicable450 0-0.032$0.70 $0.00 $0.00 -$0.02$0.00 $0.00-$0.020.00% 0.00% 0.00% 0.00%0.00% $0.00 -$0.02 -$0.02Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccount CostPurchasePrice/ UnitPurchase PriceNet, PIAPurchase PriceNet, End ItemBushing - Connecting Rod 0303-N0101-021Aluminum Bronze S$0.00$0.33$0.00 $0.330(Blank 40x30x0.5 mmm)$0.00$0.00$0.00 $0.000Meanρ= 0.270$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$0.58T1 or OEM Total Manufacturing Cost:$0.30 $0.00 $0.28 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 $0.58T1 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 $0.09Base Cost Impact to Vehicle:$0.30 $0.00 $0.28 $0.58 $0.00 $0.04 $0.03 $0.01 $0.09 $0.67 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.67TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BNA1038,29847450,00041,800,000"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 3 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Con.Rod0303Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (2of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Rod Subassembly - ConnectingPart Number:0303-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BNA1038,29847450,00041,800,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer andIn-transitInventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%18,000,000 605.00%$022978716229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:No Change Required For Packaging.File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 4 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Piston0304Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (3of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Piston - Engine, MachinedPart Number:0304-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Piston - Engine, Cast (Mini Cooper) 0304-N0101-01-011Consider weight, material andscrap (+5%) differences in casthypereutectic material.T2/T3 Internal Supplier Aluminum-B390, Cast Mold/Cast/Sinter Operator Diecast, LMC517 3 3 10.651$1.20 $43.52 $100.05 $300.15 $0.78 $0.25 $0.58 $1.61 5.00% 0.00% 0.00% 0.00% 5.00% $0.08 $1.70 $1.701B Piston - Engine, Machined (Mini Cooper) 0304-N0101-01-011T6 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, MHC442 2 4 10.000$0.00 $46.52 $100.00 $400.00$0.00$0.21 $0.90 $1.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.12 $1.121C Piston - Engine, Machined (Mini Cooper) 0304-N0101-011Machining (5% Premium onTime Accounted for in rate)T2/T3 Internal Supplier Not Applicable CNC OperatorRot./Lin. Trans. MachiningLine, TP, PREM.480 1 2 1.050.000$0.00 $35.70 $260.00 $546.00$0.00$0.07 $1.14 $1.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.21 $1.212A Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-011Consider weight and materialdifferences only as cost factorin 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% 0.00% 0.00% 0.00% $0.00 -$1.71 -$1.712B Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-011T5 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, LMC-420 1 2 10.000$0.00 $46.52 $50.00 $100.00$0.00-$0.11 -$0.24 -$0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.35 -$0.352C Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-011Machining T2/T3 Internal Supplier Not Applicable CNC OperatorRot./Lin. Trans. MachiningLine, TP-480 1 2 10.000$0.00 $35.70 $250.00 $500.00$0.00-$0.07 -$1.04 -$1.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$1.12 -$1.120##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$0.85T1 or OEM Total Manufacturing Cost:-$0.09 $0.10 $0.76 $0.77 $0.08 $0.00 $0.00 $0.00 $0.08 $0.85T1 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 $0.06 $0.05 $0.02 $0.13Base Cost Impact to Vehicle:-$0.09 $0.10 $0.76 $0.77 $0.08 $0.06 $0.05 $0.02 $0.21 $0.98$0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.98North AmericaNorth AmericaFOB Ship PointTOTAL COSTS47450,00041,800,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810MARK-UP COSTSTOOLING & INVESTMENTNA"S"=Indicates Component is Supplied directly to T1or OEM for Final orSub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplieddirectly to T1 or OEM for Final or Sub-Assembly. In addition componentmaterial cost is accounted for in T1 quote sheet.Thus component costwill only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in byT2/T3 Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Note, both the Mini and Chrysler GEMA pistons haveanodized top ringgroove and a dry-film skirt coating.File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 5 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Piston0304Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (3of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Piston - Engine, MachinedPart Number:0304-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "North AmericaNorth AmericaFOB Ship PointTOTAL COSTS47450,00041,800,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810MARK-UP COSTSTOOLING & INVESTMENTNAFull QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Cost perPieceTotalAmountLumpSumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%18,000,000 605.00%$025016229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:Packaging Type:NO CHANGE TO PACKAGINGPart Size:Parts/Layer:Number of Layers:File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 6 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 0300Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03 (4of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly of Crank Drive Subsystem ComponentsPart Number:0300-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Shaft - Crank 0301-N0101-011(OEM Mark-up included in Crankshaft Worksheet)$0.00$0.00$0.00 $0.002A Rod Subassembly - Connecting 0303-N0101-014SAC$2.66$0.67$0.00 $2.663A Piston - Engine, Machined 0304-N0101-014SAC$3.92$0.98$0.00 $3.924A Ring/Clip - Piston Pin Retainer 0304-N0101-028S$0.00$0.03$0.00 $0.245A Pin- Piston 0304-N0101-034GEMA 15Cr3(SAE5015) CaseHardenedMini 31CrMoV9 NitridedS$0.00$0.24$0.00 $0.966A Compression Ring - Piston, Top 0304-N0101-044S$0.00$0.35$0.00 $1.427A Compression Ring - Piston, 2nd 0304-N0101-054S$0.00$0.17$0.00 $0.668A Spacer/Expander/Coil Spring - Oil Ring, Piston 0304-N0101-074S$0.00$0.17$0.00 $0.689A Rail(s) - Oil Ring, Piston 0304-N0101-084S$0.00$0.06$0.00 $0.2210A Bearing - Connecting Rod to Crank Shaft 0390-N0101-018AlSn20Mn Base, AlSn10NiTurbo DIS$0.00$0.19$0.00 $1.510$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$12.27T1 or OEM Total Manufacturing Cost:$12.27 $0.00 $0.00 $12.27 $0.00 $0.00 $0.00 $0.00 $0.00 $12.27T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(6.58)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$5.69 $0.00 $0.00 $5.69 $0.00 $0.00 $0.00 $0.00 $0.00 $5.69 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$5.69Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:No Changes Required toPackagingPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)No impact to engine assembly. Assume wrist pinretaining clip labor/burden add would be offset bylabor/burden press fit pin design.File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 7 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 04Counter Balance SubsystemCase Study #0101MAQS WorksheetsFile:Counter Balance, 031908.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-04, 1 of 4Balance Shaft Subassembly 0401Manufacturing Assumption and Quote SummaryAPPENDIX G.1-04, (1of2)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Balance Shaft Assembly ( Part of Oil Pump Assembly)Part Number:0401-B0101-01Weekly Component Volume: Packaging Specification:Returnable DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Upper and Lower Housing assembly Machining 0401-B0101-11-011Assemble upper and lowerhousings, machine bearings.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base240 2 1 80.000$0.00 $35.51 $15.00 $120.00$0.00$0.30 $0.50 $0.80 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.80 $0.802A Balance Shaft Long and Short 0401-B0101-06/072Press Gears onto balanceshafts. (1 of each shaft type)T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base240 1 2 10.000$0.00 $35.51 $15.00 $30.00$0.00$0.15 $0.13 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.553A Final Assembly of Balance Shaft Assembly 0401-B0101-011Assemble Shafts into Houisngand rundown fasteners.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base240 4 1 50.000$0.00 $35.51 $15.00 $75.00$0.00$0.59 $0.31 $0.90 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.90 $0.90Purchase Part - High Impact Item (Full Cost Mapping)1A Bottom Housing Casting 0401-B0101-03-1-11Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC112 1 1 12.351$1.10 $43.52 $100.05 $100.05 $2.59 $0.39 $0.89 $3.87 5.00% 6.50% 6.00% 1.00% 18.50% $0.72 $4.58 $4.581B Bottom Housing Casting 0401-B0101-03-11Machine Casting T2/T3 Diecast, MSMC Not Applicable CNCOperator CNC Machining, LMC115 1 1.5 10.000$0.00 $35.70 $25.00 $37.50$0.00$0.31 $0.33 $0.64 5.00% 6.50% 6.00% 1.00% 18.50% $0.12 $0.75$0.752A Top Housing Balance Shaft Casting 0401-B0101-08-1-11Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC111 1 1 12.609$1.10 $43.52 $100.05 $100.05 $2.87 $0.39 $0.90 $4.17 5.00% 6.50% 6.00% 1.00% 18.50% $0.77 $4.94 $4.942B Top Housing Balance Shaft 0401-B0101-08-11Machine Casting T2/T3 Diecast, MSMC Not Applicable CNCOperator CNC Machining, LMC114 1 2 10.000$0.00 $35.70 $25.00 $50.00$0.00$0.31 $0.44 $0.75 5.00% 6.50% 6.00% 1.00% 18.50% $0.14 $0.89$0.893A Balance Shaft Short Casting 0401-B0101-06-1-1-11Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC242 3 1 11.721$0.35 $43.52 $100.06 $100.06 $0.60 $0.54 $0.41 $1.56 5.00% 6.50% 6.00% 1.00% 18.50% $0.29 $1.84 $1.843B Balance Shaft Short Casting 0401-B0101-06-1-1-11Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC242 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.41 $0.61 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.69$0.693C Balance Shaft Short Machined 0401-B0101-06-1-11Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC113 0.5 1.5 10.000$0.00 $35.70 $75.00 $112.50$0.00$0.16 $1.00 $1.16 0.50% 6.50% 6.00% 1.00% 14.00% $0.16 $1.32$1.323D Balance Shaft Short Machined 0401-B0101-06-1-11Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC132 0.5 1.25 10.000$0.00 $35.70 $65.00 $81.25$0.00$0.13 $0.61 $0.75 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.85$0.853E Balance Shaft Short Machined 0401-B0101-061Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC120 0.5 1 10.000$0.00 $35.70 $25.00 $25.00$0.00$0.15 $0.21 $0.36 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.41$0.414A Balance Shaft Short Casting 0401-B0101-07-1-1-11Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC226 3 1 12.242$0.35 $43.52 $100.06 $100.06 $0.78 $0.58 $0.44 $1.80 5.00% 6.50% 6.00% 1.00% 18.50% $0.33 $2.14 $2.144B Balance Shaft Short Casting 0401-B0101-07-1-1-11Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC242 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.41 $0.61 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.69$0.694C Balance Shaft Short Machined 0401-B0101-07-1-11Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC114 0.5 2.25 10.000$0.00 $35.70 $75.00 $168.75$0.00$0.16 $1.48 $1.64 0.50% 6.50% 6.00% 1.00% 14.00% $0.23 $1.86$1.864D Balance Shaft Short Machined 0401-B0101-07-1-11Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC142 0.5 1.3 10.000$0.00 $35.70 $65.00 $84.50$0.00$0.13 $0.60 $0.72 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.82$0.824E Balance Shaft Short Machined 0401-B0101-071Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC120 0.5 1 10.000$0.00 $35.70 $25.00 $25.00$0.00$0.15 $0.21 $0.36 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.41$0.415A Gear Balance Shaft 0401-B0101-06-2-12Machine Blank & Hob Teeth(Same process for both Gears)T2/T3 CNC Turning, MSMC LC-Steel-1215, Bar CNC Operator Balancing, MLS, LMC235 2 4.5 10.000$0.62 $35.70 $25.00 $112.50$0.00$0.30 $0.48 $0.78 0.50% 6.50% 6.00% 1.00% 14.00% $0.11 $0.89$1.795B Gear Balance Shaft 0401-B0101-06-2-12Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC360 1 1 10.000$0.00 $46.52 $50.00 $50.00$0.00$0.13 $0.14 $0.27 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.31$0.61Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Dowel Upper to lower housing alignment 0401-B0101-042S$0.00$0.03$0.00 $0.052A Bearing Shell Balance Shaft 0401-B0101-054S$0.00$0.25$0.00 $1.003A Bolt Balance Shaft Housing 0401-B0101-096S$0.00$0.06$0.00 $0.364A Cap Shaft Close out 0401-B0101-102S$0.00$0.14$0.00 $0.280$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$28.54T1 or OEM Total Manufacturing Cost:$8.53 $5.83 $10.65 $25.01 $0.68 $1.37 $1.26 $0.21 $3.53 $28.54T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.14 $1.85 $1.71 $0.71 $4.42Base Cost Impact to Vehicle:$8.53 $5.83 $10.65 $25.01 $0.82 $3.22 $2.98 $0.92 $7.95 $32.96 $0 $0Packaging Cost:$0.05Net Cost Impact to Vehicle:$33.019,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3APpendix, G.1-04, 2 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Balance Shaft Subassembly 0401Manufacturing Assumption and Quote SummaryAPPENDIX G.1-04, (1of2)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Balance Shaft Assembly ( Part of Oil Pump Assembly)Part Number:0401-B0101-01Weekly Component Volume: Packaging Specification:Returnable DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.053 $105,0000.00%2,250,000 605.00%$420250175657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.053PACKAGING CALCULATIONS:Consider additional volume as result of BalanceShaft subassembly:Packaging Type: Option #2Part Size: 190x220 x120Parts/Layer: 5 x 5Number of Layers:7File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3APpendix, G.1-04, 3 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 04Manufacturing Assumption and Quote SummaryAPPENDIX G.1-04, (2of2)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly of Balance Shaft AssemblyPart Number:Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Mount Balance Shaft Assembly to Engine 0401-B0101-011Install Balance Shaft Assemblyto block, 4 Bolts.OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM212 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.39 $0.71 $1.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.10 $1.10Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Bolt - Balance Shaft Assembly Mount to Block PC 12.94(Packaging Included in Cost) S$0.00$0.46$0.00 $1.832ABalance Shaft Assembly ( Part of Oil PumpAssembly)0401-B0101-011SAC$33.01$33.01$0.00 $33.010$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$35.95T1 or OEM Total Manufacturing Cost:$34.84 $0.39 $0.71 $35.95 $0.00 $0.00 $0.00 $0.00 $0.00 $35.95T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(33.01)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.83 $0.39 $0.71 $2.93 $0.00 $0.00 $0.00 $0.00 $0.00 $2.93 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.93Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-04, 4 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 05Cylinder Block SubsystemCase Study #0101MAQS WorksheetsFile:Cylinder Block 05, 032509.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-05, 1 of 8Cylinder Block 0501Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Block Assembly - Machined w. Studs, Plugs,etc.Part Number:0501-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACylinder Block Subassembly - Machinedw/o Studs/Plugs, etc0501-N0101-01 (Mini Cooper)1Upper cylinder blockmachiningOEMNot ApplicableCNC Operator-OEM CNC Milling, LS, HC135 0.250.000$0.00 $68.07 $250.00$0.00$0.13 $1.86 $1.980.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.98 $1.981BCylinder Block Subassembly - Machinedw/o Studs/Plugs, etc0501-B0101-01 ( Chrysler GEMA)1Machining operation adds formounting balance shaftassembly.OEMNot ApplicableCNC Operator-OEM CNC Milling, LS, HC-288 0.250.000$0.00 $68.07 $250.00$0.00-$0.06 -$0.87 -$0.930.00% 0.00% 0.00% 0.00%0.00% $0.00 -$0.93 -$0.931CCylinder Block Subassembly - Cast0501-N0101-031Main Cooper Block minusliners =29.19Chrysler GEMA Block minusliners = (33.655 + 2.08)OEM Aluminum-A380, CastNot Applicable Not Applicable89 0-6.545$1.10 $0.00 $0.00 -$7.20$0.00 $0.00-$7.205.00% 0.00% 0.00% 0.00%5.00% -$0.36 -$7.56 -$7.560##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1ACylinder Liners - Cast Iron0501-N0101-044Mini Cooper Liners = 1.9lbs/liner, Chrysler GEMAEngine = 2.44lbs/linerOEMNodular Iron, Cast Not Applicable Not Applicable450 0-0.540$0.35 $0.00 $0.00 -$0.19$0.00 $0.00-$0.190.30% 6.00% 4.00% 0.00%10.30% -$0.02 -$0.21 -$0.830##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$7.34T1 or OEM Total Manufacturing Cost:-$7.96 $0.07 $0.99 -$6.90 -$0.36 -$0.05 -$0.03 $0.00 -$0.44-$7.34T1 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 -$1.15Base Cost Impact to Vehicle:-$7.96 $0.07 $0.99 -$6.90 -$0.41 -$0.56 -$0.62 $0.00 -$1.59-$8.49 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$8.49TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31Timing 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/BeadPlateNAAssume casting speed for Chryslerand Mini Cooper Block will beapproximately the same. Thus noadditional Labor or Burden costs wereaccounted for.Assume processing speed forChrysler and Mini Cooper linerswill be approximately the same.Thus no additional Labor orBurden costs were accountedfor.NAFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 2 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Cylinder Block 0501Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Block Assembly - Machined w. Studs, Plugs,etc.Part Number:0501-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:Negligible Affect to PackagingFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 3 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bed Plate 0503Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (2of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bed Plate Assembly - Machined w. Studs, Plugs, etc.Part Number:0503-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)A1.1Bed Plate Subassembly - Cast0503-N0101-021Bed Plate casting OEMAluminum-A380,CastNot Applicable Not Applicable107 0-3.663$1.10 $0.00 $0.00 -$4.03$0.00 $0.00-$4.035.00% 0.00% 0.00% 0.00%5.00% -$0.20 -$4.23 -$4.23#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Bearing Cap - Bolt Through - Insert, Steel 0503-N0101-035Main Bearing Caps, Cast S Nodular Iron, CastNot Applicable Not Applicable554 0-0.190$0.35 $0.00 $0.00 -$0.07$0.00 $0.00-$0.075.00% 6.00% 4.00% 0.00%15.00% -$0.01 -$0.08 -$0.380#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.000$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 $0.00TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.Mini Cooper Bed Plate integrated Bearing Cap Weight = 18.01lbsChrysler Girdle has non integrated bearing capsWeight of Girdle =17.423+ Cover Contribution 0.75 -Oil FilterInlet 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% ofBedplate weight are for Bearing Caps, Thus the followingcalculations are made:Weight of Base Bed Plate Material = 79.2%x18.01 = 14.26 lbsWeight of Bearing Caps = 20.8%x18.01 = 3.75 lbsAssume casting speed forChrysler and Mini Cooper BedPlate will be approximately same.Thus no additional Labor orBurden costs were accountedfor.NAAssume casting speed forChrysler and Mini CooperBearing Caps will beapproximately the same. Thusno additional Labor or Burdencosts were accounted for.NAFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 4 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bed Plate 0503Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (2of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bed Plate Assembly - Machined w. Studs, Plugs, etc.Part Number:0503-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America0$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$4.61T1 or OEM Total Manufacturing Cost:-$4.36 $0.00 $0.00 -$4.36 -$0.22 -$0.02 -$0.01 $0.00 -$0.25-$4.61T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- ------$0.03 -$0.32 -$0.37 $0.00 -$0.72Base Cost Impact to Vehicle:-$4.36 $0.00 $0.00 -$4.36 -$0.25 -$0.34 -$0.38 $0.00 -$0.98-$5.34 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$5.34Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000Negligible Affect To Packaging31File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 5 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Piston Cooling 0504Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Squirter - Oil, Piston Cooler & RetainerPart Number:0504-N0101-01/02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)1A Bolt - Piston Cooler Valve/Retainer 0504-N0101-021Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC206 0.50.350$1.00 $35.51 $100.19 $0.35 $0.09 $0.49 $0.920.30% 6.00% 4.00% 0.00%10.30% $0.10 $1.02 $1.022A Squirter - Oil, Piston Cooler 0504-N0101-011Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC240 0.50.300$1.00 $35.51 $100.19 $0.30 $0.07 $0.42 $0.790.30% 6.00% 4.00% 0.00%10.30% $0.08 $0.87 $0.87Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemMaterial Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.89T1 or OEM Total Manufacturing Cost:$0.65 $0.16 $0.90 $1.71 $0.01 $0.10 $0.07 $0.00 $0.18 $1.89T1 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 $0.19Base Cost Impact to Vehicle:$0.65 $0.16 $0.90 $1.71 $0.01 $0.22 $0.14 $0.00 $0.37 $2.09 $0 $0Packaging Cost:$0.01Net Cost Impact to Vehicle:$2.10Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%18,000,000 605.00%$04605006229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.01$0.00 0 $0.00 0 $2.50 2 $0.00 0 $0.00 0Packaging Cost Total:$0.0101038,29847450,00041,800,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BCardboard BoxesGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT31PACKAGING CALCULAIONS:Use $0.005 additional cost for bothsquirter and bolt/check valve.Assume 250 parts/box, $2.50/Box,File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 6 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bearing Elements 0590Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bearings & Thrust Shims - Crankshaft,Part Number:0590-N0101-01/02/03Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccount CostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net, EndItemBearing - Crankshaft, 1/2 Bearing (Top)0590-N0101-015S$0.00$0.19$0.00 $0.97Bearing/Shim - Crankshaft Thrust0590-N0101-022S$0.00$0.12$0.00 $0.24Bearing - Crankshaft, 1/2 Bearing (Bottom)0590-N0101-035S$0.00$0.18$0.00 $0.920$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$2.13T1 or OEM Total Manufacturing Cost:$2.13 $0.00 $0.00 $2.13 $0.00 $0.00 $0.00 $0.00 $0.00 $2.13T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$2.13 $0.00 $0.00 $2.13 $0.00 $0.00 $0.00 $0.00 $0.00 $2.13 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.13Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer andIn-transitInventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaNo Impact to Packaging"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts are31Treat as Set, 5 Upper, 5 Lower, 2 ThrustShimsFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 7 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly-05--Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Cylinder Block Components to EnginePart Number:Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 = Material + Labor

+ BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Squirter - Oil, Piston Cooler - Assembly0504-N0101-014Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC800 10.000$0.00 $83.31 $150.19$0.00$0.10 $0.19 $0.290.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.29 $1.17Squirter - Oil, Piston Cooler - Assembly0504-N0101-014Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC1440 10.000$0.00 $83.31 $150.19$0.00$0.06 $0.10 $0.160.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.16 $0.65Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End ItemSquirter - Oil, Piston Cooler & Bolt -Piston Cooler Valve/Retainer0504-N0101-01/024SAC$8.38$2.10$0.00 $8.38Bearing Set (Upper/Lower/Thrust Shim)0590-N0101-01/02/031(UPGRADE SET) SAC$2.13$2.13$0.00 $2.13Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$12.33T1 or OEM Total Manufacturing Cost:$10.51 $0.65 $1.17 $12.33 $0.00 $0.00 $0.00 $0.00 $0.00 $12.33T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%(SAC)&T1 or OEM Mark-Up Values:(10.51)----- ----- -----$0.09 $0.86 $0.99 $0.00 $1.94Base Cost Impact to Vehicle:$0.00 $0.65 $1.17 $1.82 $0.09 $0.86 $0.99 $0.00 $1.94 $3.75 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.75Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customer andIn-transitInventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaNo Additional Packaging Affects"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts are broughtin by T2/T3 Supplier for Subassembly.31Pallet 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 Palletsize 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 WA1-3Appendix G.1-05, 8of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 06Cylinder Head SubsystemCase Study #0101MAQS WorksheetsFile:Cylinder Head 06, 032009-2.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-06, 1 of 8Cylinder Head 0601Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Head Assembly - Machined w. Studs, Plugs, etc.Part Number:0601-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACylinder Head - Machined w/o. Studs,Valves, etc.0601-N0101-011Cylinder head machining, plugassembly & testOEMNot ApplicableCNC Operator-OEM CNC Milling, LS, HC83 0.250.000$0.00 $68.07 $250.00$0.00$0.21 $3.03 $3.240.00% 0.00% 0.00% 0.00%0.00% $0.00 $3.24 $3.24Requiretooling formachining &cap assemblyRequireinvestment forcap assembly1B Cylinder Head - Heat Treat0601-N0101-021T6 Heat Treat, only considersolution step (quench andartificial age for T6 and T5approx. estimated to havesame cost impact)OEMNot ApplicableHeat Treat Operator-OEM Heat Treat, MLS, MHC81 0.250.000$0.00 $137.35 $250.00$0.00$0.42 $3.08 $3.500.00% 0.00% 0.00% 0.00%0.00% $0.00 $3.50 $3.501CCylinder Head Subassembly - CastMini Cooper0601-N0101-02-011Cylinder head casting & roughmachiningOEM Aluminum-356-T6, CastNot Applicable Not Applicable89 029.01$1.20 $0.00 $0.00 $34.81$0.00 $0.00$34.815.00% 0.00% 0.00% 0.00%5.00% $1.74 $36.55 $36.551DCylinder Head Subassembly - CastChrysler0601-N0101-02-011Cylinder head casting & roughmachiningOEMAluminum-A319-T5,CastNot Applicable Not Applicable89 0-30.99$1.15 $0.00 $0.00 -$35.64$0.00 $0.00-$35.640.00% 0.00% 0.00% 0.00%0.00% $0.00 -$35.64 -$35.640##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End Item0$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 $0.000$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 $0.00TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w.Expendable Separators9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought 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 GuidesIntake and Exhaust) 0.53 - (2 M8 Studsx80) 0.12and (2 M10 Studs x60) 0.15 + (Timing ChainCover Contribution) 1.15 = 29.84Assume casting speed forChrysler and Mini Cooper Headswill be approximately the same.Thus no additional Labor orBurden costs were accounted for.5% Added Scrap Cost For A356File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 2 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Cylinder Head 0601Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Head Assembly - Machined w. Studs, Plugs, etc.Part Number:0601-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w.Expendable Separators9,57447North America450,000North AmericaMaterial Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$7.65T1 or OEM Total Manufacturing Cost:-$0.83 $0.63 $6.11 $5.91 $1.74 $0.00 $0.00 $0.00 $1.74 $7.65T1 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 $0.54 $0.61 $0.00 $1.20Base Cost Impact to Vehicle:-$0.83 $0.63 $6.11 $5.91 $1.79 $0.54 $0.61 $0.00 $2.94 $8.85$0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$8.85Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 600.00%$00100Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.00031PACKAGING CALCULATIONS:Negligible Affect to PackagingFile:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 3 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Valve Seat 0602Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (20f5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Seat - Intake Valve, Seat - Exhaust Valve,Part Number:0602-N0101-03/04Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End Item1ASeat - Intake Valve0602-N0101-038Material difference S$0.00$0.02$0.00 $0.142ASeat - Exhaust Valve0602-N0101-048Material difference S$0.00$0.03$0.00 $0.20$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$0.34T1 or OEM Total Manufacturing Cost:$0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $0.00 $0.34T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $0.00 $0.34 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.34Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%36,000,000 600.00%$00100Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS8F.O.B3,600,000NA76,59647North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts are broughtin by T2/T3 Supplier for Subassembly.31Absolute Cost for Premium Valve SeatsIntake Valve, COMO 1207 => $0.18/ValveExhaust Valve, AR20 => $0.25/ValveBenchmark data from Munro on Baseline Intakeand Exhaust Valve Seat $0.16 and $0.22SETSPACKAGING CALCULATIONS:No Affect to PackagingFile:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 4 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bearing Caps 0606Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cap, Head (Fuel Pump & Vacuum Mount)Part Number:0606-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACap, Head (Fuel Pump & VacuumMount)0606-N0101-03-011CNC Machining S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC240 0.50.000$0.00 $43.52 $100.05$0.00$0.09 $0.42 $0.510.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.51 $0.511BCap, Head (Fuel Pump & VacuumMount)0606-N0101-03-021Die casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC240 0.50.610$1.10 $43.52 $100.05 $0.67 $0.09 $0.42 $1.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.18 $1.18Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.69T1 or OEM Total Manufacturing Cost:$0.67 $0.18 $0.83 $1.69 $0.00 $0.00 $0.00 $0.00 $0.00 $1.69T1 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 $0.11 $0.10 $0.04 $0.26Base Cost Impact to Vehicle:$0.67 $0.18 $0.83 $1.69 $0.01 $0.11 $0.10 $0.04 $0.26 $1.95 $0 $0Packaging Cost:$0.03Net Cost Impact to Vehicle:$1.98Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.032 $64,0790.00%2,250,000 605.00%$5,140124608657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.032TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w. ExpendableSeparators9,57447North America450,000North AmericaPACKAGING CALCULATIONS:Option #3 Packaging with returnabledividers.Part Size: 250x 30x45Parts per layer: 1 rows of 16Number of layers: 6Number of parts/Tote = 9631File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appnedix G.1-06, 5 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Sealing Elements 0685Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Gasket - Cylinder Head to BlockPart Number:0685-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End ItemGasket - Cylinder Head to Block0685-N0101-011Change from 2 to 3 layergasketS$0.00$1.46$0.00 $1.460$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.46T1 or OEM Total Manufacturing Cost:$1.46 $0.00 $0.00 $1.46 $0.00 $0.00 $0.00 $0.00 $0.00 $1.46T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.46 $0.00 $0.00 $1.46 $0.00 $0.00 $0.00 $0.00 $0.00 $1.46 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.46Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w.Expendable Separators9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31PACKAGING CALCULATIONS:Negligible Affect to PackagingFile:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 6 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly -06--Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Cylinder Head Components to EnginePart Number:NAWeekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACap, Head (Fuel Pump & Vacuum Mount)0606-N0101-03-011Head and cam assembly OEM Not ApplicableNot Applicable Not Applicable150 00.000$0.00 $0.00 $0.00$0.00 $0.00 $0.00$0.000.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.00 $0.00Requiretooling for capassemblyRequireinvestment forcap assembly1B Cap, Head (Fuel Pump & Vacuum Mount)0606-N0101-03-011Head & Cap Machining OEM Not Applicable Not ApplicableNot Applicable217 0.250.000$0.00 $0.00 $0.00$0.00 $0.00 $0.00$0.000.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.00 $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End Item1ASeat - Intake/Exhaust Valves0602-N0101-038Material difference SAC$2.75$0.34$0.00 $2.752ACap, Head (Fuel Pump & VacuumMount)0606-N0101-03-011Added Part SAC$1.98$1.98$0.00 $1.983A Bolt - Cap Bearing, Camshaft 0680-N0101-014Added Part S$0.00$0.08$0.00 $0.324A Gasket - Cylinder Head to Block 0685-N0101-011Modified Part SAC$1.46$1.46$0.00 $1.465A Bolt - Manifold, Exhaust 0680-N0101-1010510 Stainless or A286 Inconel S$0.00$0.36$0.00 $3.600$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$10.11T1 or OEM Total Manufacturing Cost:$10.11 $0.00 $0.00 $10.11 $0.00 $0.00 $0.00 $0.00 $0.00 $10.11T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(6.19)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$3.92 $0.00 $0.00 $3.92 $0.00 $0.00 $0.00 $0.00 $0.00 $3.92 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.92TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31NOTES:Did not add any additional costs to add Cap, Head (Fuel Pump & VacuumMount). Assumption is additional labor& burden would be negligible inhaving 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 applicationnot recommended for use w. Aluminum due toGalvanic Action510 Series Stainless or A286 (25.5Ni/14.75Cr)File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 7 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly -06--Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Cylinder Head Components to EnginePart Number:NAWeekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:Exhaust manifold bolt packaging,no change for material upgrade.Packaging cost for Cam Capbolts are included in piece price,increase in material usage only.File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 8 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 07Valve Train SubsystemCase Study #0101MAQS WorksheetsFile:Valve Trains 07, 032609.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-07, 1 of 4Valves Int.0701 & Exh.0702Manufacturing Assumption and Quote SummaryAPPENDIX G.1-07, (1of3)Printed:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Valve - Intake & Valve - OutletPart Number:0701-N0101-01 & 0702-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemValve - Inlet 0701-N0101-011Intake valves would need to be upgraded -typical upgrade would be from nitrided JISSUH11 (Fe-1.5Si, 8.5Cr, 0.5C) toSilichromeS$0.00$0.11$0.00 $0.11Valve - Outlet 0702-N0101-011Exhaust valves would need to be upgraded -typical upgrade would be from nitrided JISSUH 35 (Fe, 9Mn, 21Cr 4Ni, 0.5C and0.4N) to Inconel head and Silichrome stem.Exhaust valves on Mini Cooper Turbo DIare Sodium filled as well. This designapproach is not considered preferred andthus will note be included in cost analysis.S$0.00$0.97$0.00 $0.970$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.08T1 or OEM Total Manufacturing Cost:$1.08 $0.00 $0.00 $1.08 $0.00 $0.00 $0.00 $0.00 $0.00 $1.08T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.01 $0.08 $0.09 $0.04 $0.21Base Cost Impact to Vehicle:$1.08 $0.00 $0.00 $1.08 $0.01 $0.08 $0.09 $0.04 $0.21 $1.30 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.30Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%36,000,000 605.00%$025016459574Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES76,59610North AmericaNorth AmericaFOB Ship Point47450,00083,600,000PACKAGING CALCULATIONS:Packaging Type:NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor bothFile:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-07, 2 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Camshafts 0706Manufacturing Assumption and Quote SummaryAPPENDIX G.1-07, (2of3)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Camshaft - Intake Machine & Exhaust MachinedPart Number:0706-N0101-02 & 0706-N0101-11Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Camshaft - Intake Machined (MINI) 0706-N0101-021Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 13.886$0.35 $0.00 $0.00 $0.00 $1.36$0.00 $0.00$1.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.36 $1.362A Camshaft - Exhaust Machined (MINI) 0706-N0101-111Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 14.256$0.35 $0.00 $0.00 $0.00 $1.49$0.00 $0.00$1.49 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.49 $1.493A Camshaft - Intake Machined (MINI) 0706-B0101-021Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 1-4.260$0.35 $0.00 $0.00 $0.00 -$1.49$0.00 $0.00-$1.49 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$1.49 -$1.494A Camshaft - Exhaust Machined (MINI) 0706-B0101-111Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 1-4.630$0.35 $0.00 $0.00 $0.00 -$1.62$0.00 $0.00-$1.62 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$1.62 -$1.62Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$0.26T1 or OEM Total Manufacturing Cost:-$0.26 $0.00 $0.00 -$0.26 $0.00 $0.00 $0.00 $0.00 $0.00 -$0.26T1 or OEM Mark-Up Rates:----- ----- ----- ----- 5.00% 6.50% 6.00% 2.50% 20.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- ------$0.01 -$0.02 -$0.02 -$0.01 -$0.05Base Cost Impact to Vehicle:-$0.26 $0.00 $0.00 -$0.26 -$0.01 -$0.02 -$0.02 -$0.01 -$0.05 -$0.31 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$0.31Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-07, 3 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 0700Manufacturing Assumption and Quote SummaryAPPENDIX G.1-07, (3of3)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly Impact from upgraded Valve Train componentsPart Number:0700Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Valves Intake and Exhaust Delta (Mini$-Chrysler$)8SAC$10.37$1.30$0.00 $10.372A Camshafts Exhaust & Intake Delta (Mini$-Chrysler$)1SAC($0.31)($0.31)$0.00 -$0.310$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$10.06T1 or OEM Total Manufacturing Cost:$10.06 $0.00 $0.00 $10.06 $0.00 $0.00 $0.00 $0.00 $0.00 $10.06T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(10.06)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.00Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)No engine assembly cost impact as a result ofvalve train upgrades.File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-07, 4 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 08Timing Drive SubsystemCase Study #0101MAQS WorksheetsFile:Timing Drives 08 032608.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-08, 1 of 2Timing Wheels 0801Manufacturing Assumption and Quote SummaryAPPENDIX G.1-08, (1of1)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Sprocket - Crankshaft, Timing DrivePart Number:0801-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemSprocket - Crankshaft, Timing Drive 0801-N0101-011(Smart Sprocket royalty, mark-ups included)S$0.00$1.60$0.00 $1.600$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.60T1 or OEM Total Manufacturing Cost:$1.60 $0.00 $0.00 $1.60 $0.00 $0.00 $0.00 $0.00 $0.00 $1.60T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.60 $0.00 $0.00 $1.60 $0.00 $0.00 $0.00 $0.00 $0.00 $1.60 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.60Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:No Change to PackagingPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Timing Drives 08 032608.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-08, 2 of 2Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 10Intake SubsystemCase Study #0101MAQS WorksheetsFile:Intake Systems 10 032609.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-10, 1 of 2Intake Manifold 1001Manufacturing Assumption and Quote SummaryAPPENDIX G.1-10 (1of1)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Manifold Assembly - IntakePart Number:1001-N0101-01Weekly Component Volume: Packaging Specification:Vacuum Form ReturnablesComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Manifold - Intake, Bottom Half (Mini) 1001-N0101-01-071Injection MoldingT1 Assembly, Mark-up Applied@ Bottom.Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS254 0.5 1 11.408$1.76 $43.52 $150.01 $150.01 $2.48 $0.09 $0.59 $3.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.15 $3.151B Manifold - Intake, Top Half (Mini) 1001-N0101-01-061Injection MoldingT1 Assembly, Mark-up Applied@ Bottom.Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS267 0.5 1 10.949$1.76 $43.52 $150.01 $150.01 $1.67 $0.08 $0.56 $2.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.31 $2.310##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.001A Manifold - Intake, Bottom Half (Chrysler) 1001-B0101-01-071Injection MoldingT1 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% 0.00% 0.00% 0.00% 0.00% $0.00 -$9.62 -$9.621B Manifold - Intake, Top Half (Chrysler) 1001-B0101-01-061Injection MoldingT1 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% 0.00% 0.00% 0.00% 0.00% $0.00 -$6.62 -$6.620##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$10.78T1 or OEM Total Manufacturing Cost:-$10.66 -$0.01 -$0.10 -$10.78 $0.00 $0.00 $0.00 $0.00 $0.00-$10.78T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- ------$0.05 -$0.70 -$0.65 -$0.27 -$1.67Base Cost Impact to Vehicle:-$10.66 -$0.01 -$0.10 -$10.78 -$0.05 -$0.70 -$0.65 -$0.27 -$1.67 -$12.45 $0 $0Packaging Cost:-$0.28Net Cost Impact to Vehicle:-$12.73Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.362 $723,4040.00%2,250,000 605.00%$340212827657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.362MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:MINI COOPER INTAKE MANIFOLD = $0.08Packaging Type: Option #2Part Size: 370x280x170Parts/Layer: 4 x 3 =12Number of Layers: 531Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Equipment, Tooling and Fixturing for friction welding top andbottom sections of intake manifold together wouldbe lessexpensive for Mini versus GEMA. However since timeandburden rate differences would be minor, we have notincluded thedifference 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:3File:Intake Systems 10 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-10, 2 of 2Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 11Fuel Induction SubsystemCase Study #0101MAQS WorksheetsFile:Fuel Induction 11 032709.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-11, 1 of 12Fuel Rail-1101-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (1of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Rail - High PressurePart Number:1101-N0101-02Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Fuel Rail High Pressure 1101-N0101-021Assembly, Braze & TestT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base288 3 1 100.000$0.00 $35.51 $15.00 $150.00$0.00$0.37 $0.52 $0.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.89 $0.89Purchase Part - High Impact Item (Full Cost Mapping)1A Tube - Injector Rail 1101-N0101-02-061Turn & cross DrillT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube CNC Operator CNC Turning, MC180 0.5 1 10.600$1.65 $35.70 $45.00 $45.00 $0.99 $0.10 $0.25 $1.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.34 $1.342A Threaded Plug Rail Inlet 1101-N0101-02-051Machine & TapT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Bar CNC Operator CNC Turning, MC138 1 1.5 10.060$1.65 $35.70 $45.00 $67.50 $0.10 $0.26 $0.49 $0.84 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.84 $0.843A Boss High Pressure Sensor 1101-N0101-02-031Machine & TapT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Bar CNC Operator CNC Turning, LMC164 0.5 1.5 10.080$1.65 $35.70 $100.00 $150.00 $0.13 $0.11 $0.92 $1.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.16 $1.164A Cup Injector Port 1101-N0101-02-014PlatingT1 Assembly, Mark-up Applied@ Bottom.Plating, Fuel Rail Plating/Coating Operator Plate/Finish, SMS, MHC720 1 1 10.001$20.00 $55.17 $125.17 $125.17 $0.02 $0.08 $0.17 $0.27 0.00%0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $1.084B Cup Injector Port 1101-N0101-02-01-14Machine & Cross DrillT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Bar CNC Operator CNC Turning, HC480 2 4 10.260$1.65 $35.70 $75.00 $300.00 $0.43 $0.15 $0.63 $1.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.20 $4.815A Bracket Rail Mounting 1101-N0101-02-022StampingT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC610 0.5 1 10.147$1.64 $42.18 $100.10 $100.10 $0.24 $0.03 $0.16 $0.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.44 $0.88Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Plug Rail End 1101-N0101-02-041Stainless 304 S$0.00$0.09$0.00 $0.092A High Pressure Fuel Sensor Assembly 1101-N0101-031Pressure Sensor S$0.00$7.50$0.00 $7.500$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$18.59T1 or OEM Total Manufacturing Cost:$11.09 $1.81 $5.70 $18.59 $0.00 $0.00 $0.00 $0.00 $0.00 $18.59T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.06 $1.12 $0.74 $0.19 $2.10Base Cost Impact to Vehicle:$11.09 $1.81 $5.70 $18.59 $0.06 $1.12 $0.74 $0.19 $2.10 $20.70 $0 $0Packaging Cost:$0.07Net Cost Impact to Vehicle:$20.76Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.068 $136,6360.00%2,250,000 605.00%$2,740501152657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.068MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type: Option #3, Tote w. Vacuum FormPackPart Size: 300x55x100mmParts/Layer: 8Number of Layers:3"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 2 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (2of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Solenoid, 7 HolePart Number:1104-N0101-01Weekly Component Volume: Packaging Specification:Returnable Container & Internal DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fuel Injector Assembly 1104-N0101-011Final AssemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, LC, Base480 2 1 60.000$0.00 $37.35 $15.00 $90.00$0.00$0.16 $0.19 $0.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.34 $0.342A Seal Injector Tip 1104-N0101-01-301Overmold seal @ Injector TipT1 Assembly, Mark-up Applied@ Bottom.Nylon-HT, Inject. Electromechanical Assembly Mech Assembly, MC, Base450 1 1 10.005$4.00 $37.35 $30.00 $30.00 $0.02 $0.08 $0.07 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.173A Solenoid Body preassembled 1104-N0101-01-101Insert Windings, Ring Locator and Needle Body Assembly into Body Injector and OvermoldT1 Assembly, Mark-up Applied@ Bottom.Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base450 2 1 50.030$1.54 $37.35 $45.00 $225.00 $0.05 $0.17 $0.50 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.71 $0.714A Needle Body Assembly 1104-N0101-01-501Laser weld internal valve body (Sleeve, Needle Body, Tip and Inlet Tube)T1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base450 4 1.5 80.000$0.00 $37.35 $30.00 $360.00$0.00$0.33 $0.80 $1.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.13 $1.135A Needle Assembly 1104-N0101-01-111Assemble & Press SleeveT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base450 1 1 40.000$0.00 $37.35 $30.00 $120.00$0.00$0.08 $0.27 $0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.35 $0.356A Needle Injector 1104-N0101-01-131Laser Weld Ball and Seat toNeedleT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base514 1 1 30.000$0.00 $37.35 $30.00 $90.00$0.00$0.07 $0.18 $0.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.25 $0.257A Metering Valve assembly 1104-N0101-01-161Laser Weld Plate to ValveT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base514 1 1 20.000$0.00 $37.35 $30.00 $60.00$0.00$0.07 $0.12 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.190##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Body Injector Solenoid 1104-N0101-01-201Machine Body T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC500 0.5 5 10.140$4.56 $35.70 $45.00 $225.00 $0.64 $0.04 $0.45 $1.12 0.50% 6.50% 6.00% 1.00% 14.00% $0.16 $1.28 $1.282A Sleeve winding to inlet separator 1104-N0101-01-271Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC491 0.5 4.5 10.074$4.56 $35.70 $45.00 $202.50 $0.34 $0.04 $0.41 $0.79 0.50% 6.50% 6.00% 1.00% 14.00% $0.11 $0.90 $0.903A Sleeve Fuel Inlet 1104-N0101-01-281Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNCOperator CNC Turning, MC485 0.5 3.5 10.041$4.56 $35.70 $45.00 $157.50 $0.19 $0.04 $0.33 $0.55 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.63 $0.634A Body needle 1104-N0101-01-91Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC460 0.5 5.5 10.043$4.56 $35.70 $45.00 $247.50 $0.20 $0.04 $0.54 $0.77 0.50% 6.50% 6.00% 1.00% 14.00% $0.11 $0.88 $0.885A Inlet Tube 1104-N0101-01-211Cut and Flare T2/T3 Hydro/CNC Form, SSLC S-Steel-304,Tube Forging Operator Cold Forge, LMC360 0.5 1 10.010$1.65 $38.52 $100.09 $100.09 $0.02 $0.05 $0.28 $0.35 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.38 $0.386A Spring Seat Lower 1104-N0101-01-141Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNCOperator CNC Turning, MC450 0.25 1.5 10.0002$4.56 $35.70 $45.00 $67.50 $0.00 $0.02 $0.15 $0.17 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.19 $0.197A Needle valve 1104-N0101-01-241Centerless Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC540 0.25 1.5 10.000$0.00 $35.70 $45.00 $67.50$0.00$0.02 $0.13 $0.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.16$0.167B Needle valve 1104-N0101-01-24-011Machine Heat Treat T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC540 0.25 1.5 10.002$4.56 $35.70 $45.00 $67.50 $0.01 $0.02 $0.13 $0.15 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.178A Ball Needle seat 1104-N0101-01-231EDM Mounting Pocket T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC720 0.25 1 10.000$0.00 $35.70 $45.00 $45.00$0.00$0.01 $0.06 $0.07 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.09$0.098A Ball Needle seat 1104-N0101-01-231Grind/Lap/Wash T2/T3 CNC Turning, MSMC Not ApplicableCNC Operator CNC Turning, MC540 0.25 1.5 10.000$0.00 $35.70 $45.00 $67.50$0.00$0.02 $0.13 $0.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.16$0.168A Ball Needle seat 1104-N0101-01-231Cold Head/Machine/Heat Treat T2/T3 CNC Turning, MSMCS-Steel-440C, Bar CNC Operator Cold Forge, LMC720 0.25 1 10.0003$4.56 $35.70 $100.09 $100.09 $0.00 $0.01 $0.14 $0.15 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.179A Metering Valve 1104-N0101-01-181Machined T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNCOperator CNC Turning, MC470 0.25 3 10.005$4.56 $35.70 $45.00 $135.00 $0.02 $0.02 $0.29 $0.33 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.38 $0.3810A Plate Metering Valve 1104-N0101-01-191Stamping T2/T3 Stamp/Form, MSMC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC766 0.25 1 10.0002$1.64 $42.18 $100.10 $100.10 $0.00 $0.01 $0.13 $0.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.1711A Tip - Injector 1104-N0101-01-081EDM Micro Popping T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, MHC480 0.5 2 10.000$0.00 $35.70 $150.15 $300.30$0.00$0.04 $0.63 $0.66 0.50% 6.50% 6.00% 1.00% 14.00% $0.09 $0.76$0.7611B Tip - Injector 1104-N0101-01-08-011Metal Injection Molding T2/T3 Powder Metal, LSHC S-Steel-440-MIM Mold/Cast/Sinter Operator Powder Metal, MHC480 1 1 10.002$13.68 $43.52 $150.14 $150.14 $0.03 $0.09 $0.31 $0.43 0.70%7.00% 8.00% 2.00% 17.70% $0.08 $0.51 $0.5112A Face seal Injector to head 1104-N0101-01-4-11Powder Metal T2/T3 Powder Metal, SSLC PM-SMF-SS410 Mold/Cast/Sinter Operator Powder Metal, LMC1440 0.5 1 10.005$4.92 $43.52 $100.14 $100.14 $0.02 $0.02 $0.07 $0.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.12 $0.1213A Bracket Injector hold-down 1104-N0101-01-21Stamping T2/T3 Stamp/Form, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC600 0.5 1 10.078$0.78 $42.18 $100.10 $100.10 $0.06 $0.04 $0.17 $0.26 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30 $0.300##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Solenoid Windings 1104-N0101-01-221S$0.00$0.25$0.00 $0.252A Ring winding locator 1104-N0101-01-261S$0.00$0.08$0.00 $0.083A Spring - needle to metering valve 1104-N0101-01-151S$0.00$0.01$0.00 $0.014A Spring Needle Return 1104-N0101-01-121S$0.00$0.03$0.00 $0.035A Sleeve Screen Stop 1104-N0101-01-251S$0.00$0.01$0.00 $0.016A Screen Fuel Inlet 1104-N0101-01-61S$0.00$0.05$0.00 $0.057A circlip face seal retainer 1104-N0101-01-51S$0.00$0.02$0.00 $0.028A Compression limiter - oring 1104-N0101-01-31S$0.00$0.03$0.00 $0.039A O-Ring Injector to rail seal 1104-N0101-01-11S$0.00$0.09$0.00 $0.090$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 $0.00MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.Full QuoteModification QuoteDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 3 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (2of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Solenoid, 7 HolePart Number:1104-N0101-01Weekly Component Volume: Packaging Specification:Returnable Container & Internal DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000Full QuoteModification QuoteDifferential Quote (Quote Summary includesMaterial Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$10.95T1 or OEM Total Manufacturing Cost:$2.16 $1.47 $6.44 $10.07 $0.03 $0.41 $0.38 $0.06 $0.89 $10.95T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.08 $0.77 $0.88 $0.44 $2.16Base Cost Impact to Vehicle:$2.16 $1.47 $6.44 $10.07 $0.11 $1.18 $1.26 $0.50 $3.05 $13.11 $0 $0Packaging Cost:$0.01Net Cost Impact to Vehicle:$13.13Cost perPieceTotalAmountLump SumPayment(%)Total # ofPieces/AmortizationPeriodNumber ofService MonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.014 $108,6800.00%9,000,000 605.00%$4,1802690726229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.014PACKAGING CALCULATIONS:Packaging Type: Option #3 Tote, 42 Totes/PalletPart Size: 90x55x25 mmParts/Layer per tote: 3 x 8Number of Layers per tote: 931File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 4 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411HP-Fuel Pump 1107-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (3of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam)Part Number:1107-N0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1AFuel Pump - High Pressure w. Vol. ControlValve1107-N0101-011Final Assembly LineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base360 3 1 100.250$0.00 $35.51 $45.00 $450.00$0.00$0.30 $1.25 $1.55 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.55 $1.552A Swash Plate Drive Assembly 1107-N0101-01-091Subassembly LineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base360 1 1 80.000$0.00 $35.51 $30.00 $240.00$0.00$0.10 $0.67 $0.77 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.77 $0.773A Bellow piston cavity 1107-N0101-01-142Weld SubassemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base300 2 1 40.000$0.00 $35.51 $30.00 $120.00$0.00$0.24 $0.40 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $1.274A Bellow Retainer 1107-N0101-01-162Press Orifice Insert ontoBellows RetainerT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base600 1 1 10.000$0.00 $35.51 $30.00 $30.00$0.00$0.06 $0.05 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.225A Shaft Drive Adapter 1107-N0101-01-09-61Press Ball, Springs and InsertT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base300 0.5 1 10.000$0.00 $35.51 $30.00 $30.00$0.00$0.06 $0.10 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.16 $0.16Purchase Part - High Impact Item (Full Cost Mapping)1A Housing Fuel Pump 1107-N0101-01-25-11Extrude Housing T2/T3 Cold Forge, MSMC Aluminum-7075-T6, Ext. Extruding/Drawing Operator Cold Forge, MHC96 2 1 11.800$3.21 $54.35 $150.09 $150.09 $5.78 $1.13 $1.56 $8.47 0.50% 6.50% 6.00% 1.00% 14.00% $1.19 $9.66 $9.661B Housing Fuel Pump 1107-N0101-01-25-11Machine Housing T2/T3 CNC Milling, LSHC Not Applicable CNC Operator CNC Machining, LMC121 4 14 10.000$0.00 $35.70 $25.00 $350.00$0.00$1.18 $2.88 $4.06 0.70% 7.00% 8.00% 2.00% 17.70% $0.72 $4.78$4.781C Housing Fuel Pump 1107-N0101-01-251Assemble Ball Plugs T2/T3 Mech. Assembly, SSLC Purchased Parts General AssemblyMech Assembly, LC, Base240 1 1 40.110$1.00 $35.51 $15.00 $60.00 $0.11 $0.15 $0.25 $0.51 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.56 $0.562A Bar Stock - Check Valve Assembly 1107-N0101-01-22-11Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, HC180 0.25 2 10.040$1.65 $37.60 $85.00 $170.00 $0.07 $0.05 $0.94 $1.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.17 $1.172B Check Valve Assembly 1107-N0101-01-221Assemble components T2/T3 Mech. Assembly, SSLC Purchased Parts General Assembly Mech Assembly, MC, Base277 1 1 20.030$1.00 $35.51 $30.00 $60.00 $0.03 $0.13 $0.22 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.413A Retainer Check Valve Assembly 1107-N0101-01-24-11Machining T2/T3 CNC Turning, SSLC Ni-Al-Bronze-630000, Bar Lathe/Turning Operator CNC Turning, LC144 1 2 10.075$2.44 $37.60 $25.00 $50.00 $0.18 $0.26 $0.35 $0.79 0.30% 6.00% 4.00% 0.00% 10.30% $0.08 $0.87 $0.874A Plate - Check Valve 1107-N0101-01-202Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator CNC Turning, LC257 0.5 2 20.000$1.65 $37.60 $25.00 $100.00 $0.00 $0.07 $0.39 $0.46 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.51 $1.025A Seat - Check Valve Plate 1107-N0101-01-212Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC250 1 2.5 10.005$1.65 $37.60 $55.00 $137.50 $0.01 $0.15 $0.55 $0.71 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.78 $1.566A Retainer Check Valve 1107-N0101-01-172Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, HC251 1 3 10.050$2.44 $37.60 $85.00 $255.00 $0.12 $0.15 $1.02 $1.29 0.30% 6.00% 4.00% 0.00% 10.30% $0.13 $1.42 $2.847A Bellow piston cavity 1107-N0101-01-14-12Cut and Form Tube StockT2/T3 Hydro/CNC Form,MSMCTitanium-6AL4V, Bar Cut/Punch/Forming Operator Hydro/CNC Form, MLS, MHC225 1 1 10.010$34.37 $42.18 $150.12 $150.12 $0.34 $0.19 $0.67 $1.20 5.00%6.50% 6.00% 1.00% 18.50% $0.22 $1.42 $2.848A Spring Seat 1107-N0101-01-14-22Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC235 1 3 10.050$2.44 $37.60 $55.00 $165.00 $0.12 $0.16 $0.70 $0.98 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.09 $2.179A Top Seat and Sealing Flange 1107-N0101-01-14-32Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC230 1 3 10.110$2.44 $37.60 $55.00 $165.00 $0.27 $0.16 $0.72 $1.15 0.30% 6.00% 4.00% 0.00% 10.30% $0.12 $1.27 $2.5410A Bellow Retainer 1107-N0101-01-16-12Machining T2/T3 CNC Turning, SSLC A-Steel-41XXS, Bar Lathe/Turning Operator S-CNC Turning, MC231 2 5 10.500$0.78 $37.60 $55.00 $275.00 $0.39 $0.33 $1.19 $1.91 0.30% 6.00% 4.00% 0.00% 10.30% $0.20 $2.10 $4.2111A Piston High pressure pump 1107-N0101-01-112Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC225 2 4 1.50.030$0.78 $37.60 $55.00 $330.00 $0.02 $0.33 $1.47 $1.82 0.30% 6.00% 4.00% 0.00% 10.30% $0.19 $2.01 $4.0212A Cap Piston contact to swash plate 1107-N0101-01-102PlatingT2/T3 Plate/Finish Mech.,SSLCNot Applicable Plating/Coating Operator Plate/Finish,SMS, LMC360 0.5 1 10.000$0.00 $55.17 $100.17 $100.17$0.00$0.08 $0.28 $0.35 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.39$0.7812B Cap Piston contact to swash plate 1107-N0101-01-102Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC225 1 2 1.50.000$0.78 $37.60 $55.00 $165.00$0.00$0.17 $0.73 $0.90 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $0.99$1.9913A Casting: Swash Plate Drive Housing 1107-N0101-01-09-21Aluminum Diecast T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC286 0.5 1 10.209$1.10 $43.52 $100.05 $100.05 $0.23 $0.08 $0.35 $0.66 5.00% 6.00% 4.00% 0.00% 15.00% $0.10 $0.75 $0.7513A Swash Plate Drive Housing Machined 1107-N0101-01-09-11Machine Casting T2/T3 CNC Turning, MSMC Not Applicable Mold/Cast/Sinter Operator RTM Turning, HC, PP, Base300 0.5 1 10.000$0.00 $43.52 $200.00 $200.00$0.00$0.07 $0.67 $0.74 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.84$0.8414A Swash Plate Assy - Cast 1107-N0101-01-09-5-31Iron Casting T2/T3 Perm. Cast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, MHC286 3 1 10.219$0.35 $43.52 $150.06 $150.06 $0.08 $0.46 $0.53 $1.06 5.00% 6.50% 6.00% 1.00% 18.50% $0.20 $1.25 $1.2514B Swash Plate Assy 1107-N0101-01-09-5-21Machine Casting T2/T3 CNC Turning, MSMC Not Applicable CNC Operator RTM Turning, HC, PP, Base360 0.5 1 1.20.000$0.00 $35.70 $200.00 $240.00$0.00$0.05 $0.67 $0.72 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.82$0.8214C Swash Plate Assy 1107-N0101-01-09-5-11Heat TreatT2/T3 Plate/Finish Mech.,SSLCNot Applicable Heat Treat Operator Heat Treat, SMS, MHC250 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.40 $0.59 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.65$0.6514D Swash Plate Assy 1107-N0101-01-09-51Grind T2/T3 CNC Turning, MSMC Not Applicable CNC OperatorCNC Turning, MC124 1 1 10.000$0.00 $35.70 $45.00 $45.00$0.00$0.29 $0.36 $0.65 0.50% 6.50% 6.00% 1.00% 14.00% $0.09 $0.74$0.7415A Shaft Drive Adapter PM 1107-N0101-01-09-6-51Press and Sinter T2/T3 Powder Metal, SSLC PM-SMF-IronBase Mold/Cast/Sinter Operator Powder Metal, LMC632 1 1 10.037$1.00 $43.52 $100.14 $100.14 $0.04 $0.07 $0.16 $0.26 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.2915B Shaft Drive Adapter w/out backlash adjuster 1107-N0101-01-09-6-11Machining T2/T3 CNC Milling, SSLC Not Applicable Mold/Cast/Sinter Operator CNC Machining, LMC200 0.25 1 20.000$0.00 $43.52 $25.00 $50.00$0.00$0.05 $0.25 $0.30 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.34$0.3417A Mount Bracket HP fuel Pump 1107-N0101-01-031Ground Flat T2/T3 CNC Milling, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC600 1 1 10.000$0.00 $42.18 $100.13 $100.13$0.00$0.07 $0.17 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26$0.2617B Mount Bracket HP fuel Pump 1107-N0101-01-03-11Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC391 0.5 1 11.080$0.55 $42.18 $100.13 $100.13 $0.59 $0.05 $0.26 $0.90 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $1.00 $1.0018A Spacer - Mount Bracket - swash plate retainer 1107-N0101-01-021Fineblanked T2/T3 Fine Blank, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC600 1 1 10.000$0.00 $42.18 $100.13 $100.13$0.00$0.07 $0.17 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26$0.2618B Spacer - Mount Bracket 1107-N0101-01-02-11Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC439 0.5 1 10.557$0.55 $42.18 $100.13 $100.13 $0.31 $0.05 $0.23 $0.58 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.64 $0.6419A Diaphragm Temperature Compensating 1107-N0101-01-081Assemble & Test T2/T3 Mech. Assembly, SSLC PurchasedParts Cut/Punch/Forming Operator Mech Assembly, LC, Base300 1 1 30.120$1.00 $42.18 $15.00 $45.00 $0.12 $0.14 $0.15 $0.41 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.45 $0.4519BTop Stamping Diaphragm TemperatureCompensating1107-N0101-01-08-11Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC621 0.5 1 10.042$0.45 $42.18 $100.10 $100.10 $0.02 $0.03 $0.16 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.24 $0.2419CBottom Stamping Diaphragm TemperatureCompensating1107-N0101-01-08-21Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC643 0.5 1 10.018$0.45 $42.18 $100.10 $100.10 $0.01 $0.03 $0.16 $0.20 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.22 $0.2220A Fitting Fuel Inlet 1107-N0101-01-061Machine T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC123 0.5 1.5 10.120$1.65 $37.60 $55.00 $82.50 $0.20 $0.15 $0.67 $1.02 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.13 $1.13MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 5 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411HP-Fuel Pump 1107-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (3of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam)Part Number:1107-N0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000Full QuoteModificationDifferential Quote (Quote Summary includesPurchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A 4mm Ball Plug NA7Purchase Part B1A$0.00$0.01$0.07 $0.002A Seat Fuel Outlet Fitting NA1Purchase Part B1A$0.00$0.04$0.04 $0.003A Check Ball 1107-N0101-01-22-31Purchase Part B3A$0.00$0.01$0.01 $0.004A Spring Check Ball 1107-N0101-01-22-41Purchase Part B3A$0.00$0.01$0.01 $0.005A Seat Check Ball 1107-N0101-01-22-51Purchase Part B3A$0.00$0.01$0.01 $0.006A Spring Check Valve 1107-N0101-01-231Purchase Part S$0.00$0.03$0.00 $0.037A Seat Check valve spring 1107-N0101-01-182Purchase Part S$0.00$0.06$0.00 $0.128A Spring - Check Valve 1107-N0101-01-192Purchase Part S$0.00$0.01$0.00 $0.029A Spring Bellow return 1107-N0101-01-132Purchase Part S$0.00$0.05$0.00 $0.1010A Pin Guide Pin Guide2Purchase Part S$0.00$0.02$0.00 $0.0411A O-Ring Bellow OD sealing 1107-N0101-01-152Purchase Part S$0.00$0.07$0.00 $0.1412A Tip Insert - Orifice 1107-N0101-01-16-22Purchase Part S$0.00$0.02$0.00 $0.0413A Spring HP piston 1107-N0101-01-122Purchase Part S$0.00$0.06$0.00 $0.1214A Seal Swash Plate shaft 1107-N0101-01-09-41Purchase Part S$0.00$0.19$0.00 $0.1915A Bearing Roller, Swash Plate Shaft 1107-N0101-01-09-81Purchase Part S$0.00$0.23$0.00 $0.2316A Bearing Roller Thrust, Swash Plate 1107-N0101-01-09-71Purchase Part S$0.00$0.65$0.00 $0.6517A Spring Backlash adjust 1107-N0101-01-09-6-42Purchase Part S$0.00$0.01$0.00 $0.0218A Ball Backlash Adjust 1107-N0101-01-09-6-32Purchase Part S$0.00$0.01$0.00 $0.0219A Ball Seat/Retainer 1107-N0101-01-09-6-22Purchase Part S$0.00$0.01$0.00 $0.0220A O-ring OD Seal to pump housing 1107-N0101-01-09-31Purchase Part S$0.00$0.08$0.00 $0.0821A Bolt Mount bracket 1107-N0101-01-013Purchase Part S$0.00$0.05$0.00 $0.1522A Oil Swash Plate cavity 1107-N0101-01-261Purchase Part S$0.00$0.20$0.00 $0.2023ASpring Stamping Diaphragm Temperature Compensating1107-N0101-01-08-31Purchase Part B19A$0.00$0.07$0.07 $0.0023B Diaphragm Temperature Compensating 1107-N0101-01-08-3-11Purchase Part B19A$0.00$0.05$0.05 $0.0024 Screen Fuel Inlet 1107-N0101-01-071Purchase Part S$0.00$0.08$0.00 $0.0825 Solenoid Fuel Pump Control 1107-N0101-01-051Purchase Part S$0.00$10.00$0.00 $10.0026 Bolt Control Solenoid - fuel pump 1107-N0101-01-042Purchase Part S$0.00$0.06$0.00 $0.1227Seal - High Pressure Fuel Pump to CylinderHead1185-N0101-011Purchase Part S$0.00$0.08$0.00 $0.08Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$58.06T1 or OEM Total Manufacturing Cost:$16.99 $8.24 $28.32 $53.55 $0.33 $2.30 $1.76 $0.14 $4.52 $58.06T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.41 $4.06 $4.65 $2.32 $11.44Base Cost Impact to Vehicle:$16.99 $8.24 $28.32 $53.55 $0.73 $6.36 $6.40 $2.46 $15.96 $69.50 $0 $0Packaging Cost:$0.11Net Cost Impact to Vehicle:$69.61Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.111 $221,1600.00%2,250,000 605.00%$3,880571008657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.111PACKAGING CALCULATIONS:Packaging Type: Option #3 TotesPart Size: 100x100x100Parts/Layer: 4x2Number of Layers: 3"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 6 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Pipe Assembly 1170-R5Manufacturing Assumption and Quote SummaryAPPENDIX G1-11, (4of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Pipe Assembly - Fuel, High Pressure, Pump to RailPart Number:1170-N0101-01Weekly Component Volume: Packaging Specification:ReturnableComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Pipe - Fuel, High Pressure, Pump to Rail 1170-N0101-011Assembly Tube Nuts and Flare Tube EndsT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base225 1 1 20.000$0.00 $35.51 $15.00 $30.00$0.00$0.16 $0.13 $0.29 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.29 $0.29Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Stock HP pump to rail 1170-N0101-01-011CNC Tube BendingT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC171 0.25 1 10.060$1.65 $42.18 $100.12 $100.12 $0.10 $0.06 $0.58 $0.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.74 $0.742A Tube Nut HP pump to rail 1170-N0101-01-022Screw Machine Hex Bar StockT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube CNC Operator CNC Turning, LC288 0.5 2 10.088$1.65 $35.70 $25.00 $50.00 $0.15 $0.06 $0.17 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 $0.76Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.80T1 or OEM Total Manufacturing Cost:$0.39 $0.34 $1.06 $1.80 $0.00 $0.00 $0.00 $0.00 $0.00 $1.80T1 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 $0.11 $0.07 $0.02 $0.20Base Cost Impact to Vehicle:$0.39 $0.34 $1.06 $1.80 $0.01 $0.11 $0.07 $0.02 $0.20 $2.00 $0 $0Packaging Cost:$0.008Net Cost Impact to Vehicle:$2.01Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.008 $16,1170.00%2,250,000 605.00%$2,02087200657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.008MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING 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 T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 7 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Fuel Rail 1101 - GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (5of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Rail AssemblyPart Number:1101-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fuel Rail Assembly 1101-B0101-011Flow Drill Injector Cups to RailT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base157 2 1 10.000$0.00 $35.51 $45.00 $45.00$0.00$0.45 $0.29 $0.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.74 $0.742A Fuel Rail Assembly 1101-B0101-011Projection Weld BracketsT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base257 1 1 10.000$0.00 $35.51 $15.00 $15.00$0.00$0.14 $0.06 $0.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.20 $0.203A Fuel Rail Assembly 1101-B0101-011Assembly end caps and inlettube and braze weld assembly.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base157 2 1 40.000$0.00 $35.51 $15.00 $60.00$0.00$0.45 $0.38 $0.84 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.84 $0.840##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Injector Rail 1101-B0101-01-31Cut to length and back extrudeinletT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube Cut/Punch/Forming Operator Stamp/Form, SMS, LMC300 1 1 10.563$1.65 $42.18 $100.10 $100.10 $0.93 $0.14 $0.33 $1.40 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.40 $1.402A End Cap 1101-B0101-01-42StampT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC706 0.5 1 10.011$1.64 $42.18 $100.10 $100.10 $0.02 $0.03 $0.14 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.383A Cup Injector Port 1101-B0101-01-54StampT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC735 0.5 1 10.006$1.64 $42.18 $100.10 $100.10 $0.01 $0.03 $0.14 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.704A Bracket Rail Mounting 1101-B0101-01-62StampT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC679 0.5 1 10.095$1.64 $42.18 $100.10 $100.10 $0.16 $0.03 $0.15 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.675A Inlet Tube 1101-B0101-01-71Bend & FormT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC600 0.5 1 10.029$1.65 $42.18 $100.12 $100.12 $0.05 $0.04 $0.17 $0.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.25 $0.250##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$5.18T1 or OEM Total Manufacturing Cost:$1.36 $1.46 $2.35 $5.18 $0.00 $0.00 $0.00 $0.00 $0.00 $5.18T1 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 $0.31 $0.21 $0.05 $0.58Base Cost Impact to Vehicle:$1.36 $1.46 $2.35 $5.18 $0.02 $0.31 $0.21 $0.05 $0.58 $5.76 $0 $0Packaging Cost:$0.07Net Cost Impact to Vehicle:$5.83MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 8 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Fuel Rail 1101 - GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (5of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Rail AssemblyPart Number:1101-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000Full QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.069 $138,9630.00%2,250,000 605.00%$4,180331728657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.069PACKAGING CALCULATIONS:Packaging Type: Option #3Part Size:Parts/Layer: 1X12Number of Layers 3Pallet 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, =$20.00File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 9 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11 (6of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Low Pressure, 4 HolePart Number:1104-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Injector Tip Assembly 1104-B0101-01-801Assemble Injector TipT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General AssemblyMech Assembly, MC, Base1800 0.5 1 40.000$0.00 $35.51 $30.00 $120.00$0.00$0.01 $0.07 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.082A Injector Needle Assembly 1104-B0101-01-701Assemble Injector NeedleT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General AssemblyMech Assembly, MC, Base480 0.5 2 30.000$0.00 $35.51 $30.00 $180.00$0.00$0.04 $0.38 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $0.413A Needle Body Assembly 1104-B0101-01-711Assemble Injector NeedleT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General AssemblyMech Assembly, MC, Base480 2 2 70.000$0.00 $35.51 $30.00 $420.00$0.00$0.15 $0.88 $1.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.02 $1.024A Solenoid Body Overmold 1104-B0101-01-721Overmold Solenoid BodyT1 Assembly, Mark-up Applied@ Bottom.Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base450 2 2 10.030$1.54 $37.35 $45.00 $90.00 $0.05 $0.17 $0.20 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $0.415A Final Assembly 1104-B0101-01-731Final Assembly & TestT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base480 2 2 60.000$0.00 $35.51 $45.00 $540.00$0.00$0.15 $1.13 $1.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.27 $1.27Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Inlet 1104-B010101-01-211Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator CNC Turning, LC471 2 5.5 10.035$0.78 $35.70 $25.00 $137.50 $0.03 $0.15 $0.29 $0.47 0.50% 6.50% 6.00% 1.00% 14.00% $0.07 $0.54 $0.542A Inlet Sleeve Adaptor Stamped 1104-B0101-01-501Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, MHC1200 0.5 1 10.008$0.78 $42.18 $125.10 $125.10 $0.01 $0.02 $0.10 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.14 $0.143A Coupler Fuel Inlet 1104-B0101-01-281Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, LC450 1 4 10.023$0.78 $35.70 $35.00 $140.00 $0.02 $0.08 $0.31 $0.41 0.50% 6.50% 6.00% 1.00% 14.00% $0.06 $0.47 $0.474A Body, Needle 1104-B0101-01-091Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, LC465 1 4 10.049$0.78 $35.70 $35.00 $140.00 $0.04 $0.08 $0.30 $0.42 0.50% 6.50% 6.00% 1.00% 14.00% $0.06 $0.47 $0.475A Can Solenoid Housing 1104-B0101-01-511Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC720 0.5 1 10.043$0.78 $42.18 $100.10 $100.10 $0.03 $0.03 $0.14 $0.20 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.22 $0.226A Needle Valve 1104-B0101-01-241Stamped/Forged T2/T3 Stamp/Form, SSLC A-Steel-41XXS,Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC600 0.5 1 10.005$0.78 $42.18 $100.10 $100.10 $0.00 $0.04 $0.17 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.237A Needle Valve Seat 1104-B0101-01-521Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, LC643 0.5 2.5 10.005$0.78 $35.70 $35.00 $87.50 $0.00 $0.03 $0.14 $0.17 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.19 $0.198A Bracket Injector Hold down 1104-B0101-01-02-011Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC1800 0.25 1 10.021$0.65 $42.18 $100.10 $100.10 $0.01 $0.01 $0.06 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.088B Bracket Injector Hold down 1104-B0101-01-021Heat Treat & Plate T2/T3 Heat Treat, SSLC General Underhood Plating Plating/Coating Operator Plate/Finish,SMS, LMC1800 0.5 1 10.001$15.00 $55.17 $100.17 $100.17 $0.02 $0.02 $0.06 $0.09 0.30%6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.099A Injector Tip Housing 1104-N0101-01-081Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, MC450 1 4.5 10.003$0.78 $35.70 $55.00 $247.50 $0.00 $0.08 $0.55 $0.63 0.50% 6.50% 6.00% 1.00% 14.00% $0.09 $0.72 $0.7210A Plate - Injector Tip 1104-N0101-01-08-021Stamp T2/T3 CNC Turning, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC3600 0.25 1 10.000$0.78 $42.18 $100.10 $100.10 $0.00 $0.00 $0.03 $0.03 0.50% 6.50% 6.00% 1.00% 14.00% $0.00 $0.04 $0.0410B Plate - Injector Tip 1104-N0101-01-08-011Laser Injector Holes T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, LMC3600 0.25 1 10.000$0.00 $35.70 $125.15 $125.15$0.00$0.00 $0.03 $0.04 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.04$0.0411A Tip Relief Plate 1104-B0101-01-701Stamp T2/T3 Stamp/Form, SSLC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC2057 0.25 1 10.000$0.78 $42.18 $100.10 $100.10 $0.00 $0.01 $0.05 $0.05 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Sleeve Screen-Screen Stop 1104-B0101-01-251S$0.00$0.01$0.00 $0.012A Screen, Fuel Inlet 1104-B0101-01-061S$0.00$0.05$0.00 $0.053A Retainer Metering valve, Upper Spring Seat 1104-B0101-01-171S$0.00$0.02$0.00 $0.024A Ball Needle Seat 1104-B0101-01-231(Used Pricing from MiniInjector)S$0.00$0.41$0.00 $0.415A Spring - Needle Return 1104-B0101-01-121S$0.00$0.03$0.00 $0.036A Solenoid Winding Assembly 1104-N0101-01-221S$0.00$0.15$0.00 $0.157A O-Ring Injector to Rail Seal 1104-B0101-01-611S$0.00$0.09$0.00 $0.098A O-Ring Injector to Head 1104-B0101-01-621S$0.00$0.05$0.00 $0.059A Sleeve Injector Head 1104-B0101-01-631S$0.00$0.02$0.00 $0.0210A Injector Slip Washer 1104-B0101-01-641S$0.00$0.01$0.00 $0.01Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$7.31T1 or OEM Total Manufacturing Cost:$1.03 $1.04 $4.86 $6.93 $0.01 $0.19 $0.16 $0.02 $0.38 $7.31T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.05 $0.51 $0.59 $0.29 $1.44Base Cost Impact to Vehicle:$1.03 $1.04 $4.86 $6.93 $0.06 $0.70 $0.74 $0.31 $1.82 $8.76 $0 $0Packaging Cost:$0.01Net Cost Impact to Vehicle:$8.77MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 10 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11 (6of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Low Pressure, 4 HolePart Number:1104-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000Full QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.012 $97,9610.00%9,000,000 605.00%$4,42022103686229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.012PACKAGING CALCULATIONS:Packaging Type: Option #3 TotePart Size: 90x55x25 mmParts/Layer: 3 x 8Number of Layers: 9File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 11 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly-1100 R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (7of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:OEM Assembly of Fuel Induction Components to EnginePart Number:1100Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fuel Rail - High Pressure 1101-N0101-021Install Fuel Rail to CylinderHead(Two AdditionalFasteners Over Base GEMAEngine)OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM257 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.32 $0.58 $0.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.91 $0.912A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-014Install Fuel Injectors toCylinder Head, ConsideredWash to Base EngineOEM Assembly, Mark-upApplied @ Bottom.Not Applicable Not Applicable Not Applicable451 1 1 10.000$0.00 $0.00 $0.00 $0.00$0.00 $0.00 $0.00$0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00Fuel Pump - High Pressure w. Vol.Control Valve(Driven-Off Intake Cam)1107-N0101-011Install Fuel Pump to CylinderHead, 3 FastenersOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM171 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.49 $0.88 $1.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.36 $1.36Pipe Assembly - Fuel, High Pressure, Pump toRail1170-N0101-011Install High Pressure PipeBetween Fuel Rail and Pump.Run Down Two Tube NutsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM257 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.32 $0.58 $0.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.91 $0.91Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Fuel Rail - High Pressure (w. HP Sensor) 1101-N0101-021(Mini Cooper) SAC$20.76$20.76$0.00 $20.762A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-014(Mini Cooper) SAC$52.50$13.13$0.00 $52.503AFuel Pump - High Pressure w. Vol.Control Valve(Driven-Off Intake Cam)1107-N0101-011(Mini Cooper) SAC$69.61$69.61$0.00 $69.614APipe Assembly - Fuel, High Pressure, Pump toRail1170-N0101-011(Mini Cooper) SAC$2.01$2.01$0.00 $2.010$0.00$0.00$0.00 $0.005A Fuel Rail Assembly 1101-B0101-011Chrysler GEMA SAC($5.83)($5.83)$0.00 -$5.836A Fuel Injector Assembly - Low Pressure, 4 Hole 1104-B0101-014Chrysler GEMA SAC($35.07)($8.77)$0.00 -$35.070$0.00$0.00$0.00 $0.007A Bolt - Fuel Pump (to head) 1180-N0101-023S$0.00$0.03$0.00 $0.098A Bolt - Fuel Rail (to head) 1180-N0101-012S$0.00$0.03$0.00 $0.06Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$107.31T1 or OEM Total Manufacturing Cost:$104.14 $1.13 $2.04 $107.31 $0.00 $0.00 $0.00 $0.00 $0.00 $107.31T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(103.99)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.15 $1.13 $2.04 $3.33 $0.00 $0.00 $0.00 $0.00 $0.00 $3.33 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.33Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:No Packaging Considerations Required.Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 12 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 12Exhaust SubsystemCase Study #0101MAQS WorksheetsFile:Exhaust Subsystem 12 033009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-12, 1 of 6Manifold Exhaust 1201Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12 (1of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Manifold - Exhaust, Dual WallPart Number:1201-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-021CastT1 Assembly, Mark-up Applied@ Bottom.NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC141 6 1.5 27.760$3.50 $43.52 $150.07 $450.21 $27.16 $1.85 $3.19 $32.20 10.00% 0.00% 0.00% 0.00% 10.00% $3.22 $35.42 $35.421B Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-011Heat Treat, Pre MachineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Heat Treat Operator Heat Treat, MLS, MHC129 1 3 10.000$0.00 $46.52 $250.00 $750.00$0.00$0.36 $5.83 $6.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $6.20 $6.201C Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-011MachiningT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC120 3 3 1.50.000$0.00 $43.52 $45.00 $202.50$0.00$1.09 $1.69 $2.78 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.78 $2.782A Manifold - Exhaust, (Chrysler) 1201-B0101-01-021CastT1 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% 0.00% 0.00% 0.00% 5.00% -$0.39 -$8.28 -$8.282B Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-01-011Heat Treat, Pre MachineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Heat Treat Operator Heat Treat, MLS, MHC-125 1 2.5 10.000$0.00 $46.52 $250.00 $625.00$0.00-$0.37 -$5.00 -$5.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$5.37 -$5.372C Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-011MachiningT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC-120 3 3 10.000$0.00 $43.52 $45.00 $135.00$0.00-$1.09 -$1.13 -$2.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$2.21 -$2.210##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$28.52T1 or OEM Total Manufacturing Cost:$22.64 $0.03 $3.03 $25.70 $2.83 $0.00 $0.00 $0.00 $2.83 $28.52T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.14 $1.85 $1.71 $0.71 $4.42Base Cost Impact to Vehicle:$22.64 $0.03 $3.03 $25.70 $2.97 $1.85 $1.71 $0.71 $7.25 $32.95 $0 $0Packaging Cost:-$0.12Net Cost Impact to Vehicle:$32.829,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesCasting & Machining Assumptions:Casting: Assumption processing timeincrease due to part complexity and materialgrade is offset by reduction in materialvolume.Machining: 50% premium paid onmachining NiResist material over basenodular cast iron.File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 2 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Manifold Exhaust 1201Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12 (1of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Manifold - Exhaust, Dual WallPart Number:1201-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.152 $303,1910.00%2,250,000 605.00%$38079872657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.152PACKAGING CALCULATIONS:MINIPackaging Type: Option #2Part Size:320x120X115Parts/Layer: 3x10Number of Layers: 7Cost $0.03/PartPACKAGING CALCULATIONS:GEMAPackaging Type: Option #2Part Size: 380x280x130Parts/Layer:3x4Number of Layers: 6Cost = $0.076/PartFile:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 3 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Exh. Brkt's-Heat Shields 1275Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12, (2of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Bracket Subassembly- Heat Shield, Top, TurboPart Number:1275-N0101-02Weekly Component Volume: Packaging Specification:(Included in piece cost)Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Bracket Subassembly- Heat Shield, Top, Turbo 1275-N0101-021Install Ceramic Fiber Paper(Fiberfrax 440), crimp and form.T1 Assembly, Mark-up Applied@ Bottom.Fiberfrax 440 General Assembly Mech Assembly, MC, Base450 1 1 1256$0.01 $35.51 $30.00 $30.00 $1.77 $0.08 $0.07 $1.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.91 $1.910##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.91T1 or OEM Total Manufacturing Cost:$1.77 $0.08 $0.07 $1.91 $0.00 $0.00 $0.00 $0.00 $0.00 $1.91T1 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 $0.20Base Cost Impact to Vehicle:$1.77 $0.08 $0.07 $1.91 $0.01 $0.11 $0.08 $0.00 $0.20 $2.11 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.11Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:31Full QuoteModificationDifferential Quote (Quote Summary includesMaterial Size "In^2" and MaterialCost $/Inch^2.File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 4 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Exhaust Sealing 1285Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12, (3of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Bracket Subassembly - Exhaust Manifold w. Integrated GasketPart Number:1275-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1ABracket Subassembly - Exhaust Manifold w.Integrated Gasket1275-N0101-011Upgrade from 2 to 3 layerexhaust gasket. Onlyconsidering gasket, noconsideration required for heatshield mounting.S$0.00$0.95$0.00 $0.950$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$0.95T1 or OEM Total Manufacturing Cost:$0.95 $0.00 $0.00 $0.95 $0.00 $0.00 $0.00 $0.00 $0.00 $0.95T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.95 $0.00 $0.00 $0.95 $0.00 $0.00 $0.00 $0.00 $0.00 $0.95 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.95Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 5 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1200Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12 (4 of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Vehicle Operations or Engine Assembly of Exhaust ComponentsPart Number:1200Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemManifold Exhaust 1201-N0101-011SAC$32.82$32.82$0.00 $32.82Exhaust Brackets/Heat Shields 1275-N0101-021SAC$2.11$2.11$0.00 $2.11Exhaust Sealing 1275(85)-N0101-011SAC$0.95$0.95$0.00 $0.95Nut- Manifold Exhaust to Cylinder Head 1280-N0101-0110S$0.00$0.18$0.00 $1.83Nut - Turbo to C.C. Catalytic Converter 1280-N0101-063S$0.00$0.02$0.00 $0.06Nut - Exhaust Manifold to Turbo 1280-N0101-074(0.193-0.05) S$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$37.77T1 or OEM Total Manufacturing Cost:$37.77 $0.00 $0.00 $37.77 $0.00 $0.00 $0.00 $0.00 $0.00 $37.77T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(35.88)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.89 $0.00 $0.00 $1.89 $0.00 $0.00 $0.00 $0.00 $0.00 $1.89 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.89Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:No change to packagingPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesCover cost of Nut-Exhaust Manifold to Turbo in AirInduction Engine Assembly Cost Sheet.No differential labor/burden costs incurred to assemblyexhaust system components.File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 6 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 13Lubrication SubsystemCase Study #0101MAQS WorksheetsFile:13 Lubrication Subsystem 032309.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-13, 1 of 11Oil Pump 1302Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13 (1of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Oil Pump AssemblyPart Number:1302-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Oil Pump Assembly 1302-N0101-011Increase in Pump Capacity 15-20% (13%PCJ & 5% Turbo)S$0.00$3.08$0.00 $3.080$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.08T1 or OEM Total Manufacturing Cost:$3.08 $0.00 $0.00 $3.08 $0.00 $0.00 $0.00 $0.00 $0.00 $3.08T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.02 $0.22 $0.25 $0.12 $0.61Base Cost Impact to Vehicle:$3.08 $0.00 $0.00 $3.08 $0.02 $0.22 $0.25 $0.12 $0.61 $3.69 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.69Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:No Packaging Updates RequiredPackaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 2 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Filter Cooler Assembly 1306Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13 (2of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Filter Cooler Assembly - Oil (Includes Seals)Part Number:1306-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Oil Cooler Adapter/Base Plate Subassembly 1306-N0101-01-02-1A1Toggle Lock Adaptor andBase Plate TogetherS Not Applicable General Assembly Mech. Assembly, MC300 10.000$0.00 $35.51 $125.19$0.00$0.12 $0.42 $0.540.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.54 $0.542A Oil Cooler 1306-N0101-01-021Fixture and Braze Weld S Not Applicable General Assembly Mech. Assembly, MC180 10.000$0.00 $35.51 $125.19$0.00$0.20 $0.70 $0.890.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.89 $0.893AFilter Cooler Assembly - Oil (Includes Seals &aux1306-N0101-011Final Assembly of filter/coolerassembly (Only ConsiderTurbo/DI Driven Costs)S Not Applicable General Assembly Mech. Assembly, MC240 50.000$0.00 $35.51 $125.19$0.00$0.74 $0.52 $1.260.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.26 $1.26Purchase Part - High Impact Item (Full Cost Mapping)1A Housing Oil Filter Preassembled 1306-N0101-01-081Casting (50% Mass Attributedto Turbo/DI oil cooler features)S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC160 10.900$1.10 $43.52 $100.05 $0.99 $0.27 $0.63 $1.890.30% 6.00% 4.00% 0.00%10.30% $0.19 $2.08 $2.081B Housing Oil Filter Preassembled 1306-N0101-01-081Machine Casting Features(Hole Attributed to Turbo/DIOnly)S Not Applicable Mold/Cast/Sinter Operator Perm. Cast,MHC150 10.000$0.00 $43.52 $150.06$0.00$0.29 $1.00 $1.290.30% 6.00% 4.00% 0.00%10.30% $0.13 $1.42 $1.422A Oil Cooler Adapter Plate 1306-N0101-01-02-11Stamping SAluminum-3003/4047B,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC480 0.50.253$2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.780.30% 6.00% 4.00% 0.00%10.30% $0.08 $0.86 $0.863A Oil Cooler Base Plate 1306-N0101-01-02-21Stamping SAluminum-3003/4047B,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC480 0.50.253$2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.780.30% 6.00% 4.00% 0.00%10.30% $0.08 $0.86 $0.864A Oil Cooler Cooling Plate stack-Lance 1306-N0101-01-02-35Stamping SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC581 10.018$1.65 $42.18 $100.10 $0.03 $0.07 $0.17 $0.270.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.30 $1.525A Oil Cooler Cooling Plate stack 1306-N0101-01-02-317Stamping SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC1161 0.50.018$1.65 $42.18 $100.10 $0.03 $0.02 $0.09 $0.130.30% 6.00% 4.00% 0.00%10.30% $0.01 $0.15 $1.046A Oil Cooler Top Plate 1306-N0101-01-02-41Stamping SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC581 0.50.062$1.65 $42.18 $100.10 $0.10 $0.04 $0.17 $0.310.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.34 $0.34Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Gasket housing to block Oil 1306-N0101-01-091S$0.00$0.07$0.00 $0.072A Gasket housing to block - coolant 1306-N0101-01-101S$0.00$0.06$0.00 $0.063A Gasket Oil Cooler Odd Shape 1306-N0101-01-071S$0.00$0.06$0.00 $0.064A Gasket Oil Cooler Square 1306-N0101-01-061S$0.00$0.06$0.00 $0.065A Gasket Oil Cooler Oval 1306-N0101-01-051S$0.00$0.06$0.00 $0.066A Gasket Oil Cooler Round 1306-N0101-01-041S$0.00$0.05$0.00 $0.057A Bolt Oil Cooler to housing 1306-N0101-01-035S$0.00$0.01$0.00 $0.068ATube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1370-N0101-011SAC$4.09$4.09$0.00 $4.090$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 $0.00TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w. ExpendableSeparators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 3 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Filter Cooler Assembly 1306Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13 (2of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Filter Cooler Assembly - Oil (Includes Seals)Part Number:1306-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w. ExpendableSeparators109,57447450,0001450,000Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$15.33T1 or OEM Total Manufacturing Cost:$7.02 $2.23 $5.31 $14.57 $0.02 $0.44 $0.29 $0.00 $0.76 $15.33T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:(4.09)----- ----- -----$0.08 $1.00 $0.92 $0.38 $2.38Base Cost Impact to Vehicle:$2.93 $2.23 $5.31 $10.48 $0.10 $1.44 $1.21 $0.38 $3.13 $13.61 $0 $0Packaging Cost:$0.16Net Cost Impact to Vehicle:$13.78Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.068 $136,7780.00%2,250,000 605.00%$20068484657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.10$1.00 8 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.164Option #2 Packaging with expendabletier dividers and pads.Two parts nested together.Part Packaging Volume: 300x360x120Parts/Layer = 3x4=12Number of Layers = 731File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 4 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Turbo to Block 1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (3of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly - Oil, Turbo to Engine BlockPart Number:1370Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-021Assemble End Fittings and Orings onto Tube and Crimp inPlace. Pressure TestS Not Applicable General Assembly Mech. Assembly, LC240 20.000$0.00 $35.51 $100.19$0.00$0.30 $0.42 $0.710.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.71 $0.71Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-21Tube Bending S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form, SMS, LMC360 0.50.210$0.62 $42.18 $100.12 $0.13 $0.06 $0.28 $0.470.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.47 $0.471B Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-11Flare Tube Ends S Not Applicable Cut/Punch/Forming OperatorHydro/CNC Form, SMS, LMC240 10.210$0.00 $42.18 $100.12$0.00$0.18 $0.42 $0.590.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.59 $0.591C Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-31Plate SGeneral Underhood PlatingPlating/Coating OperatorPlate/Finish, SMS, MHC720 10.001$15.00 $55.17 $125.17 $0.02 $0.08 $0.17 $0.270.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.29 $0.292A Fitting Tube End 1370-N0101-02-42Forge Blank S MC-Steel-1018, Bar Forging Operator ColdForge, LMC900 0.50.165$0.55 $38.52 $100.09 $0.09 $0.02 $0.11 $0.220.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.22 $0.452B Fitting Tube End 1370-N0101-02-42Machine S Not Applicable CNC Operator CNC Milling, SMS, LC360 0.50.000$0.00 $35.70 $100.15$0.00$0.05 $0.28 $0.330.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.33 $0.662C Fitting Tube End 1370-N0101-02-42Plate SGeneral Underhood PlatingPlating/Coating OperatorPlate/Finish, SMS, MHC1800 10.001$15.00 $55.17 $125.17 $0.02 $0.03 $0.07 $0.120.30% 6.00% 4.00% 0.00%10.30% $0.01 $0.13 $0.25Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A O-ring - Tube Fitting 1370-N0101-02-31S$0.00$0.06$0.00 $0.060$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.48T1 or OEM Total Manufacturing Cost:$0.42 $0.81 $2.20 $3.43 $0.00 $0.03 $0.02 $0.00 $0.05 $3.48T1 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 $0.21 $0.14 $0.00 $0.36Base Cost Impact to Vehicle:$0.42 $0.81 $2.20 $3.43 $0.01 $0.24 $0.16 $0.00 $0.41 $3.84 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$3.90TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 5 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Turbo to Block 1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (3of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly - Oil, Turbo to Engine BlockPart Number:1370Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.055 $110,2060.00%2,250,000 605.00%$4,420252304657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.055Option #3: Returnable Totes andDividersPart Nest Size: 300x30x90Parts per layer 16Number of Layers = 3= 48 Parts per ToteFile:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 6 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Oil Cool-Turbo1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (4of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to TurbochargerPart Number:1370-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fitting Hose Oil Cooler to Turbo 1306-N0101-01-11-21Braze weld Tube Fitting toBracket MountS Not Applicable General Assembly Mech. Assembly, LC257 10.000$0.00 $35.51 $100.19$0.00$0.14 $0.39 $0.530.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.53 $0.531BTube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1306-N0101-01-11(1370-N0101-01)1Crimp End Fitting to Hose andAdd Protective Heat Shield,Oring and ClampS Not Applicable General Assembly Mech. Assembly, LC240 30.000$0.00 $35.51 $100.19$0.00$0.44 $0.42 $0.860.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.86 $0.86Purchase Part - High Impact Item (Full Cost Mapping)1A Hose Oil Cooler to Turbo 1306-N0101-01-11-11Extrude & Shape Hose SSBR-Fiber Rein.W. Outer Wrap,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC545 1.50.007$2.05 $54.35 $100.04 $0.01 $0.15 $0.18 $0.350.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.35 $0.352A Tube Fitting end 1306-N0101-01-11-2-11Machining S LC-Steel-1215, Tubing CNC Operator CNC Turning, LMC200 0.250.150$0.62 $35.70 $100.00 $0.09 $0.04 $0.50 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.643A Bracket Tube Fitting end attach 1306-N0101-01-11-2-1-11Fine blank, LMC S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC1000 0.50.207$0.45 $42.18 $100.13 $0.09 $0.02 $0.10 $0.210.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.24 $0.24Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item1A Collar Tube fitting attachment 1306-N0101-01-11-2-1-21S$0.00$0.05$0.00 $0.052A Heat Shield, Hose 1306-N0101-01-11-21S$0.00$0.75$0.00 $0.753A Hose Clamp 1306-N0101-01-11-31S$0.00$0.22$0.00 $0.224A O-ring 1306-N0101-01-11-41S$0.00$0.06$0.00 $0.060$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$3.68T1 or OEM Total Manufacturing Cost:$1.27 $0.80 $1.59 $3.66 $0.00 $0.01 $0.01 $0.00 $0.02 $3.68T1 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 $0.22 $0.15 $0.00 $0.38Base Cost Impact to Vehicle:$1.27 $0.80 $1.59 $3.66 $0.01 $0.23 $0.16 $0.00 $0.40 $4.06 $0 $0Packaging Cost:$0.03Net Cost Impact to Vehicle:$4.09TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 7 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Oil Cool-Turbo1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (4of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to TurbochargerPart Number:1370-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.026 $51,9500.00%2,250,000 605.00%$5,86096480657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.026Packaging Option #3: Returnable Totes &DividersPart Nesting Size: 220x30x30Parts per Layer: 15Layers per Tote: 9File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 8 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Oil - Synthetic 1399Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (5of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Oil - SyntheticPart Number:1399-N0101-08Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A OIL - ENGINE 0W-40 ILSAC GF3 MS-10725 NA1S$0.00$4.00$0.00 $4.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$4.00T1 or OEM Total Manufacturing Cost:$4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $0.00 $4.00T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $0.00 $4.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$4.00Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Standard Pallet L4'xW4'xD3'Area = 122cm x 114 cm = 1440 sq. cmDepth = 86 cmPart Size:Parts Per Layer:Parts Per Pallet:"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 9 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1300Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (6of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Additional or Revised Lubrication Components to EnginePart Number:1300-N0101-00Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-021Install Tube Assembly toEngineOEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.822ATube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1306-N0101-01-11(1370-N0101-01)1Install Hose to TurboAssembly, Run Down BoltOEM Not Applicable General Assembly-OEM Engine Assembly, OEM240 10.000$0.00 $83.31 $150.21$0.00$0.35 $0.63 $0.970.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.97 $0.973A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-011Install Filter Cooler Assemblyand Run Down 4 BoltsOEM Not Applicable General Assembly-OEM Engine Assembly, OEM180 10.000$0.00 $83.31 $150.21$0.00$0.46 $0.83 $1.300.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.30 $1.30Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccount CostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item1ABolt - Tube Assembly , Oil, Turbo Outlet & BlockI1380-N0101-062Banjo Bolts S$0.00$0.24$0.00 $0.482AWasher - Bolt - Tube Assembly , Oil, TurboOutlet1380-N0101-094Banjo Washers S$0.00$0.03$0.00 $0.123A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-021SAC$3.84$3.84$0.00 $3.844A Bolt hose oil cooler to turbo 1306-N0101-01-121S$0.00$0.05$0.00 $0.055A Bolt - Filter Cooler Assembly 1380-N0101-084S$0.00$0.07$0.00 $0.286A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-011SAC$13.78$13.78$0.00 $13.787ATube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1370-N0101-011SAC$4.09$4.09$0.00 $4.09Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$26.72T1 or OEM Total Manufacturing Cost:$22.64 $1.46 $2.63 $26.72 $0.00 $0.00 $0.00 $0.00 $0.00 $26.72T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 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 $0.00Base Cost Impact to Vehicle:$0.93 $1.46 $2.63 $5.02 $0.00 $0.00 $0.00 $0.00 $0.00 $5.02 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$5.02Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging Cost for Fasteners included infastener piece price.No other packaging costs required."S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 10 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1300Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (6of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Additional or Revised Lubrication Components to EnginePart Number:1300-N0101-00Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 11 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 14Cooling SubsystemCase Study #0101MAQS WorksheetsFile:14 Cooling System 033109.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-14, 1 of 9Pump-Aux. Coolant 1401 R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Pump- Auxiliary Coolant, ElectricPart Number:1401-N0101-02Weekly Component Volume: Packaging Specification:Returnable PackagingComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Charge Impeller Assembly 1401-N0101-02-3-11Magnetize Impeller AssemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base240 1 1 10.000$0.00 $35.51 $30.00 $30.00$0.00$0.15 $0.13 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.272A Pump-Auxiliary Coolant Final Assembly 1401-N0101-021Final AssemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base240 2 1 90.000$0.00 $35.51 $30.00 $270.00$0.00$0.30 $1.13 $1.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.42 $1.42INTENTIONAL BLANK SPACE0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.003A Pump-Auxiliary Coolant, Electric Subassembly 1401-N0101-00 (New P/N )1Assemble pump to bracket andhoses to pump.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base200 4 1 40.000$0.00 $35.51 $15.00 $60.00$0.00$0.71 $0.30 $1.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.01 $1.010##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Motor Housing Assembly 1401-N0101-02-1-11Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS360 0.5 1 20.110$6.02 $43.52 $150.01 $300.02 $0.66 $0.06 $0.83 $1.56 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.56 $1.562A End Cap Motor close out 1401-N0101-02-1-21Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS769 0.5 1 10.025$3.86 $43.52 $150.01 $150.01 $0.10 $0.03 $0.20 $0.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.32 $0.323A Housing Impellor Cavity 1401-N0101-02-2-11Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS626 0.5 1 10.094$3.86 $43.52 $150.01 $150.01 $0.36 $0.03 $0.24 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.644A Impellor Water Pump 1401-N0101-02-3-1-11Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS333 0.5 1 1.50.100$6.02 $43.52 $150.01 $225.02 $0.60 $0.07 $0.68 $1.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.34 $1.34INTENTIONAL BLANK SPACE0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.001ABracket Subassembly - Auxiliary Pump to OilFilter/Cooler Ass'y1475-N0101-01-031Progressive Die BlankT1 Assembly, Mark-up Applied@ Bottom.LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC600 0.5 1 10.808$0.45 $42.18 $100.10 $100.10 $0.36 $0.04 $0.17 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $0.571BBracket Subassembly - Auxiliary Pump to OilFilter/Cooler Ass'y1475-N0101-01-021Stage Tooling (3 Stage)T1 Assembly, Mark-up Applied@ Bottom.Not Applicable Cut/Punch/Forming Operator Stamp/Form,SMS, LMC240 1 1 10.000$0.00 $42.18 $100.10 $100.10$0.00$0.18 $0.42 $0.59 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.59 $0.591CBracket Subassembly - Auxiliary Pump to OilFilter/Cooler Ass'y1475-N0101-01-011Apply CoatingT2/T3 Plate/Finish Mech., SSLCPowder Coat Plating/Coating Operator Plate/Finish, SMS, LMC720 1 1 10.010$20.00 $55.17 $100.17 $100.17 $0.20 $0.08 $0.14 $0.42 0.30%6.00% 4.00% 0.00% 10.30% $0.04 $0.46 $0.46Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Terminals 1401-N0101-02-711Terminals Tin Plate S$0.00$0.09$0.00 $0.092A O-ring - Motor Housing to Impeller Housing 1401-N0101-02-721Silicone S$0.00$0.04$0.00 $0.043A AlNiCo Magnets 1401-N0101-02-734(Uncharged, Approx 10x20x2.5) S$0.00$0.45$0.00 $1.804A Motor Winding Assembly 1401-N0101-02-1-1-31S$0.00$4.50$0.00 $4.505A PCB Motor Control Assembly 1401-N0101-02-1-1-21S$0.00$5.00$0.00 $5.006A E-Clip1401-N0101-02-51S$0.00$0.02$0.00 $0.027A Heat Sink 1401-N0101-02-61S$0.00$0.05$0.00 $0.058A Screw Impellor cavity to motor housing 1401-N0101-02-2-24S$0.00$0.02$0.00 $0.089A Bolt pump to bracket 1401-N0101-02-023S$0.00$0.01$0.00 $0.0310A Wire Harness Retention Clips NA2Required for O2 Sensor, ThusNo Cost Impact.S$0.00$0.00$0.00 $0.0011AHose Assembly - Oil Filer/Cooler Ass'y toAuxiliary Pump1470-N0101-041SAC$2.07$2.07$0.00 $2.0712A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-031SAC$3.81$3.81$0.00 $3.81Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$25.67T1 or OEM Total Manufacturing Cost:$19.78 $1.63 $4.22 $25.63 $0.00 $0.02 $0.02 $0.00 $0.04 $25.67T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:(5.88)----- ----- -----$0.18 $1.80 $2.05 $1.03 $5.06Base Cost Impact to Vehicle:$13.90 $1.63 $4.22 $19.75 $0.18 $1.82 $2.07 $1.03 $5.10 $24.85 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$24.919,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 2 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Pump-Aux. Coolant 1401 R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Pump- Auxiliary Coolant, ElectricPart Number:1401-N0101-02Weekly Component Volume: Packaging Specification:Returnable PackagingComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.059 $118,2030.00%2,250,000 605.00%$500236243657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.059PACKAGING CALCULATIONS:Packaging Type: Option 1 w. Expendable DividersPart Size: 340X130X90Parts/Layer:3X9Number of Layers: 9File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 3 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose,Oil Cool. - Aux Pump 1470DManufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (2of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Oil Filer/Cooler Ass'y to AuxiliaryPumpPart Number:1470-N0101-04Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-11Extrude & Shape Hose SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC273 1.50.127$1.85 $54.35 $100.04 $0.23 $0.30 $0.37 $0.900.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.90 $0.902A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-11Assemble Sheathing and GlueClampsS Purchased Parts General AssemblyMech Assembly, LC,Base240 2$0.62$1.00 $35.51 $15.00 $0.62 $0.30 $0.06 $0.980.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.98 $0.980##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Sheath Hose Protection (Aux-Filter) 1470-N0101-04-21Nylon B2B$0.00$0.28$0.28 $0.002A Hose Clamp 1470-N0101-03-12Steel- Zinc Phosphate B2B$0.00$0.17$0.34 $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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.88T1 or OEM Total Manufacturing Cost:$0.85 $0.59 $0.43 $1.88 $0.00 $0.00 $0.00 $0.00 $0.00 $1.88T1 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 $0.19Base Cost Impact to Vehicle:$0.85 $0.59 $0.43 $1.88 $0.01 $0.11 $0.08 $0.00 $0.19 $2.07 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.07Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%2,250,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging Options: Shipped w. Aux.Pump, No Packaging Costs Required"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 4 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y-Turbo-Aux Pump 1470CManufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Auxiliary Pump to TurboPart Number:1470-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fitting Hose End 1306-N0101-01-11-51Cold Headed Tubing S LC-Steel-1215, Tubing Forging Operator Cold Forge, LMC720 0.50.092$0.62 $38.52 $100.09 $0.06 $0.03 $0.14 $0.220.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.22 $0.222A Fitting Tube End 1370-N0101-02-41CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC240 0.50.270$0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.760.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.76 $0.763A Tube 1306-N0101-01-11-5-21Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form,SMS, LMC360 0.50.030$0.62 $42.18 $100.12 $0.02 $0.06 $0.28 $0.360.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.36 $0.364A Tube Assembly - Banjo Joint for Turbo 1470-N0101-03-031Assemble, Braze and Plate S Not Applicable General Assembly Mech. Assembly, LC257 20.000$0.00 $35.51 $100.19$0.00$0.28 $0.39 $0.670.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.67 $0.675A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-021Extrude & Shape Hose SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC581 1.50.091$1.85 $54.35 $100.04 $0.17 $0.14 $0.17 $0.480.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.48 $0.486A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-011Overmold Banjo Tube to Hose S Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS360 10.007$1.74 $43.52 $100.01 $0.01 $0.12 $0.28 $0.410.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.41 $0.417A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-031Assemble Sheathing andGlue ClampS Purchased Parts General AssemblyMech Assembly, LC,Base200 1$0.30$1.00 $35.51 $15.00 $0.30 $0.18 $0.08 $0.550.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.55 $0.550##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hose Clamp 1470-N0101-03-11Steel- Zinc Phosphate B3C$0.00$0.17$0.17 $0.002A Sheath Hose protection (Turbo) 1470-N0101-03-21B3C$0.00$0.13$0.13 $0.00$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.45T1 or OEM Total Manufacturing Cost:$0.72 $0.87 $1.85 $3.45 $0.00 $0.00 $0.00 $0.00 $0.00 $3.45T1 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 $0.21 $0.14 $0.00 $0.36Base Cost Impact to Vehicle:$0.72 $0.87 $1.85 $3.45 $0.01 $0.21 $0.14 $0.00 $0.36 $3.81 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.81109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 5 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y-Turbo-Aux Pump 1470CManufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Auxiliary Pump to TurboPart Number:1470-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000Packaging Options: Shipped w. Aux.Pump, No Packaging Costs RequiredFile:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 6 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y Turbo-Thermo, 1470Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Turbo Assembly to Thermostat/Coolant ValvePart Number:1470-N0101-02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube Assembly Prefabricated 1470-N0101-02-04-011Assemble, Braze S Not Applicable General AssemblyMech Assembly,HC, Base240 10.000$0.00 $35.51 $45.00$0.00$0.15 $0.19 $0.340.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.34 $0.342A Tube Assembly Prefabricated 1470-N0101-02-04-021Projection Weld Brkt S Not Applicable General AssemblyMech Assembly, LC,Base240 10.000$0.00 $35.51 $15.00$0.00$0.15 $0.06 $0.210.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.21 $0.213A Tube Assembly Prefabricated 1470-N0101-02-04-021Plating SGeneral UnderhoodPlatingPlating/Coating Operator Plate/Finish, MLS, LMC720 10.001$15.00 $55.17 $150.17 $0.02 $0.08 $0.21 $0.300.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.30 $0.304AHose Assembly - Turbo Assembly toThermostat/Coolant Valve1470-N0101-021Assemble SBR Tube with twohose clampsS Not Applicable General AssemblyMech Assembly, LC,Base240 20.000$0.00 $35.51 $15.00$0.00$0.30 $0.06 $0.360.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.36 $0.360##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Fitting Tube End 1370-N0101-02-41CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC240 0.50.270$0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.760.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.76 $0.762A Bracket Tube Attachment 1470-N0101-02-4-41Stamping S LC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, SMS,LMC600 0.50.233$0.45 $42.18 $100.10 $0.10 $0.04 $0.17 $0.310.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.31 $0.313A Preformed Tube 10mm OD 1470-N0101-02-4-11Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form,SMS, LMC360 0.50.150$0.62 $42.18 $100.12 $0.09 $0.06 $0.28 $0.430.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.43 $0.434A Preformed Tube 14mm OD 1470-N0101-02-4-21Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form,SMS, LMC240 10.060$0.62 $42.18 $100.12 $0.04 $0.18 $0.42 $0.630.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.63 $0.635A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-11Extrude & Shape Hose SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC933 1.50.055$1.85 $54.35 $100.04 $0.10 $0.09 $0.11 $0.300.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.30 $0.30Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchase Price/UnitPurchase PriceNet, PIAPurchasePrice Net, EndItem1A Hose Clamp small ID 1470-N0101-02-21S$0.00$0.24$0.00 $0.242A Hose Clamp large ID 1470-N0101-02-31S$0.00$0.26$0.00 $0.260$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$4.13T1 or OEM Total Manufacturing Cost:$1.02 $1.10 $2.01 $4.13 $0.00 $0.00 $0.00 $0.00 $0.00 $4.13T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.03% 6.00% 4.00% 0.00% 10.03%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.25 $0.17 $0.00 $0.41Base Cost Impact to Vehicle:$1.02 $1.10 $2.01 $4.13 $0.00 $0.25 $0.17 $0.00 $0.41 $4.55 $0 $0Packaging Cost:$0.04Net Cost Impact to Vehicle:$4.59TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 7 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y Turbo-Thermo, 1470Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Turbo Assembly to Thermostat/Coolant ValvePart Number:1470-N0101-02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.015 $30,3950.00%2,250,000 605.00%$200152378657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.03$1.00 10 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.042Pallet Option #1 w. Expendable Tier PadsPart Size 400x80x90Parts/Layer = 3x14Number of Layers = 9File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 8 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1400Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Additional or Revised Assembly Components to EnginePart Number:1400-N0101-00Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Assembly Pump-Aux. Coolant Subassembly 1401-N0101-02+ Subs1Mount Auxiliary Pump to OilCooler/Filter (2 Screws), MakeElectrical ConnectionConstrain wire in ClipsOEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.822AHose Assembly, Turbo -Aux Pump and HoseAss'y- Turbo - Thermostat Valve1470-N0101-02/031Install and run Banjo bolt (x2)@ turbo.OEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.823AHose, Oil Cooler to Aux Pump and Hose Ass'yTurbo Thermostat Valve to Thermostat Valve1470-N0101-02/041Press on Tubes and releaseHose ClampsOEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.824AHose Assembly - Turbo Assembly toThermostat/Coolant Valve1470-N0101-020Run fastener to secure HoseAssembly Bracket to EngineOEM Not Applicable General Assembly-OEM Engine Assembly, OEM300 10.000$0.00 $83.31 $150.21$0.00$0.28 $0.50 $0.780.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.78 $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Bolt-Hose, coolant Inlet and Outlet @ Turbo 1480-N0101-062Banjo Bolts S$0.00$0.24$0.00 $0.482AWasher banjo Bolt-Hose, coolant Inlet and Outlet @1480-N0101-134Banjo Washers S$0.00$0.02$0.00 $0.083ABolt-Hose Bracket, coolant Inlet and Outlet @Turbo1480-N0101-141S$0.00$0.12$0.00 $0.124A Bolt Aux pump bracket to oil cooler 1480-N0101-073S$0.00$0.02$0.00 $0.065A Pump- Auxiliary Coolant, Electric 1401-N0101-021SAC$24.91$24.91$0.00 $24.916AHose Assembly - Turbo Assembly toThermostat/Coolant Valve1470-N0101-021SAC$4.59$4.59$0.00 $4.59Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$35.68T1 or OEM Total Manufacturing Cost:$30.23 $1.94 $3.50 $35.68 $0.00 $0.00 $0.00 $0.00 $0.00 $35.68T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(29.49)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.74 $1.94 $3.50 $6.19 $0.00 $0.00 $0.00 $0.00 $0.00 $6.19 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$6.19Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging Cost for Fasteners included infastener piece price.No other packaging costs required."S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 9 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 15Air Induction Charging SubsystemCase Study #0101MAQS WorksheetsFile:15 Air Induction Charging System 040109A.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-15, 1 of 16Turbo Assembly 1501 Rev 5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(1of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Turbo Charging AssemblyPart Number:1501-N0101-01Weekly Component Volume: Packaging Specification:ReturnableComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Block Turbo shaft support - cooling & lub 1201-N0101-01-101Subassembly Center SupportBlockT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base177 4 1 80.000$0.00 $35.51 $30.00 $240.00$0.00$0.80 $1.35 $2.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.15 $2.152A Housing Turbo Exhaust 1201-N0101-01-091Subassembly Exhaust HousingT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base180 2 1 30.000$0.00 $35.51 $15.00 $45.00$0.00$0.39 $0.25 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.643A Final Assembly Line 1501-N0101-011Final Product Assembly & TestT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base180 11 1 130.000$0.00 $35.51 $15.00 $195.00$0.00$2.17 $1.08 $3.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.25 $3.254A Turbine Shaft Assembly - Welded 1201-N0101-01-01-24-011Electron Beam Weld TurbineImpeller to Shaft and GrindProfileT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base180 1 1 20.000$0.00 $35.51 $30.00 $60.00$0.00$0.20 $0.33 $0.53 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.53 $0.535ATurbo Assembly Center Housing RotatingAssembly (CHRA) Balancing1201-N0101-01-01-241High Speed Dynamic BalancingT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base180 4.5 3 10.000$0.00 $35.51 $45.00 $135.00$0.00$0.89 $0.75 $1.64 10.00% 0.00% 0.00% 0.00% 10.00% $0.16 $1.80 $1.80Purchase Part - High Impact Item (Full Cost Mapping)1A Housing Turbo Intake Casting 1201-N0101-01-07-01-21Cast Intake Housing T2/T3 Sand Cast, MSMC Aluminum-A319-T5, Cast Mold/Cast/Sinter Operator Sand Cast, HMC120 6 1 12.200$1.15 $43.52 $150.07 $150.07 $2.53 $2.18 $1.25 $5.96 5.00% 6.50% 6.00% 1.00% 18.50% $1.10 $7.06 $7.061B Housing Turbo Intake Casting 1201-N0101-01-07-01-11T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC125 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.37 $0.80 $1.17 0.50% 6.50% 6.00% 1.00% 14.00% $0.16 $1.34$1.341C Housing Turbo Intake Casting 1201-N0101-01-07-011Machine Intake Housing T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC119 3 7 10.000$0.00 $35.70 $45.00 $315.00$0.00$0.90 $2.64 $3.53 0.50% 6.50% 6.00% 1.00% 14.00% $0.49 $4.03$4.032A Block Center Bearing Support 1201-N0101-01-30-021Sand Casting T2/T3 Sand Cast, MSMC SiMo Ductile Iron,Cast Mold/Cast/Sinter Operator Sand Cast, HMC160 9 1 13.500$0.60 $43.52 $150.07 $150.07 $2.10 $2.45 $0.94 $5.49 5.00% 6.50% 6.00% 1.00% 18.50% $1.01 $6.50 $6.502B Block Center Bearing Support 1201-N0101-01-30-011T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC167 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.28 $0.60 $0.88 0.50% 6.50% 6.00% 1.00% 14.00% $0.12 $1.00$1.002C Block Center Bearing Support 1201-N0101-01-301Critical Faces Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC122 4 8 10.000$0.00 $35.70 $45.00 $360.00$0.00$1.18 $2.96 $4.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.58 $4.72$4.723A Housing Turbo Exhaust 1201-N0101-01-09-01-021Sand Casting T2/T3 Sand Cast, MSMC NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC120 6 1 16.890$3.50 $43.52 $150.07 $150.07 $24.12 $2.18 $1.25 $27.54 5.00% 6.50% 6.00% 1.00% 18.50% $5.10 $32.64 $32.643B Housing Turbo Intake Casting 1201-N0101-01-09-01-011T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC114 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.41 $0.88 $1.28 0.50% 6.50% 6.00% 1.00% 14.00% $0.18 $1.46$1.463C Housing Turbo Exhaust 1201-N0101-01-09-011Machine Casting T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC, PREM.114 3 6 10.000$0.00 $35.70 $55.00 $330.00$0.00$0.94 $2.90 $3.84 0.50% 6.50% 6.00% 1.00% 14.00% $0.54 $4.38$4.384A Support Plate intake side 1201-N0101-01-26-021Diecasting T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC275 1 1 10.421$1.10 $43.52 $100.05 $100.05 $0.46 $0.16 $0.36 $0.99 5.00% 6.00% 4.00% 0.00% 15.00% $0.15 $1.13 $1.134B Support Plate intake side 1201-N0101-01-26-011T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC267 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.17 $0.38 $0.55 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.63$0.634C Support Plate intake side 1201-N0101-01-261Machine Casting T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, MC129 1 2 10.000$0.00 $35.70 $45.00 $90.00$0.00$0.28 $0.70 $0.98 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.08$1.085A Heat Shield Exhaust shaft seal 1201-N0101-01-291Stamp T2/T3 Stamp/Form, SSLC Inconel-713C, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC621 0.5 1 10.029$6.00 $42.18 $100.10 $100.10 $0.17 $0.03 $0.16 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.416A Anti-rotate plate - bushing 1201-N0101-01-341Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC720 0.5 1 10.005$0.65 $42.18 $100.10 $100.10 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.197A Plate Brass Oil Diverter 1201-N0101-01-19-11Stamp Part T2/T3 Stamp/Form, SSLC Bronze-89320, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC679 0.5 1 10.027$2.56 $42.18 $100.10 $100.10 $0.07 $0.03 $0.15 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.27 $0.277B Plate Brass Oil Diverter 1201-N0101-01-191Machine Oil Pass Through T2/T3 CNC Milling, MSMC NotApplicable CNC Operator CNC Machining, LMC257 0.25 1 20.000$0.00 $35.70 $25.00 $50.00$0.00$0.03 $0.19 $0.23 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.26$0.268A Bushing - Turbine Shaft 1201-N0101-01-321Screw Machine T2/T3 CNC Turning, MSMC Bronze-89320, Bar CNC Operator S-CNC Turning, HC117 1 2.5 10.070$2.56 $35.70 $85.00 $212.50 $0.18 $0.31 $1.82 $2.30 0.50% 6.50% 6.00% 1.00% 14.00% $0.32 $2.63 $2.639A Seal Carrier support plate mount 1201-N0101-01-27-011Screw Machine T2/T3 CNC Turning, MSMCA-Steel-4140, BarCNC Operator S-CNC Turning, LC160 1 2 10.040$0.78 $35.70 $35.00 $70.00 $0.03 $0.22 $0.44 $0.69 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.79 $0.7910A Valve Exhaust Dump 1201-N0101-01-09-01-05-021Investment Cast T2/T3 Invest. Cast, LSHC Nickel AlloyGen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC120 7 1 10.150$5.00 $43.52 $150.08 $150.08 $0.75 $2.54 $1.25 $4.54 5.00% 7.00% 8.00% 2.00% 22.00% $1.00 $5.54 $5.5410B Valve Exhaust Dump 1201-N0101-01-09-01-05-011Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC118 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.39 $0.84 $1.24 0.50% 6.50% 6.00% 1.00% 14.00% $0.17 $1.41$1.4110C Valve Exhaust Dump 1201-N0101-01-09-01-051Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM.180 0.5 1 10.000$0.00 $35.70 $35.00 $35.00$0.00$0.10 $0.19 $0.29 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.33$0.3311A Arm - Valve to Shaft 1201-N0101-01-09-01-06-021Investment Cast T2/T3 Invest. Cast, LSHC Nickel AlloyGen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC120 7 1 10.153$5.00 $43.52 $150.08 $150.08 $0.77 $2.54 $1.25 $4.55 5.00% 7.00% 8.00% 2.00% 22.00% $1.00 $5.56 $5.5611B Arm - Valve to Shaft 1201-N0101-01-09-01-06-011Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC118 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.39 $0.84 $1.24 0.50% 6.50% 6.00% 1.00% 14.00% $0.17 $1.41$1.4111C Arm - Valve to Shaft 1201-N0101-01-09-01-061Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM.120 0.5 1 10.000$0.00 $35.70 $35.00 $35.00$0.00$0.15 $0.29 $0.44 0.50% 6.50% 6.00% 1.00% 14.00% $0.06 $0.50$0.5012A Block control rod attachment 1201-N0101-01-09-01-101Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC960 3 1 10.042$2.40 $43.52 $100.06 $100.06 $0.10 $0.14 $0.10 $0.34 5.00% 6.00% 4.00% 0.00% 15.00% $0.05 $0.39 $0.3912B Block control rod attachment 1201-N0101-01-09-01-101Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM.200 0.5 1 10.000$0.00 $35.70 $35.00 $35.00$0.00$0.09 $0.18 $0.26 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30$0.3013A Arm Dump Valve Control 1201-N0101-01-09-01-081Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC960 3 1 10.050$2.40 $43.52 $100.06 $100.06 $0.12 $0.14 $0.10 $0.36 5.00% 6.00% 4.00% 0.00% 15.00% $0.05 $0.41 $0.4114A Impeller Intake 1201-N0101-01-16-031Rubber/Plaster Mold T2/T3 Invest. Cast, LSHC Aluminum-356-T6, Cast Mold/Cast/Sinter Operator Invest. Cast,HMC180 5 1.25 10.064$1.20 $43.52 $150.08 $187.60 $0.08 $1.21 $1.04 $2.33 25.00%7.00% 8.00% 2.00% 42.00% $0.98 $3.31 $3.3114B Impeller Intake 1201-N0101-01-16-021T6 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC174 1 1.5 10.000$0.00 $46.52 $100.00 $150.00$0.00$0.27 $0.86 $1.13 20.00% 6.50% 6.00% 1.00% 33.50% $0.38 $1.51 $1.5114C Impeller Intake 1201-N0101-01-16-011Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC164 1 2.5 10.000$0.00 $35.70 $45.00 $112.50$0.00$0.22 $0.69 $0.91 20.00% 6.50% 6.00% 1.00% 33.50% $0.30 $1.21 $1.2114D Impeller Intake 1201-N0101-01-1612 Plane Dynamic Balance T2/T3 CNC Turning, MSMC NotApplicable Precision Assembly Balancing, SMS, MHC180 4.5 3 10.000$0.00 $25.74 $45.00 $135.00$0.00$0.64 $0.75 $1.39 20.00% 6.50% 6.00% 1.00% 33.50% $0.47 $1.86 $1.8615A Turbine Wheel 1201-N0101-01-01-24-051Investment Cast T2/T3 Invest. Cast, LSHC Inconel-713,Cast Mold/Cast/Sinter Operator Invest. Cast, HMC180 9 1.5 10.075$6.00 $43.52 $150.08 $225.12 $0.45 $2.18 $1.25 $3.88 25.00%7.00% 8.00% 2.00% 42.00% $1.63 $5.51 $5.5115B Turbine Wheel 1201-N0101-01-01-24-041Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC178 1 1.5 10.000$0.00 $46.52 $100.00 $150.00$0.00$0.26 $0.84 $1.11 20.00% 6.50% 6.00% 1.00% 33.50% $0.37 $1.48 $1.4815C Turbine Wheel 1201-N0101-01-01-24-031Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC180 0.5 1 10.000$0.00 $35.70 $45.00 $45.00$0.00$0.10 $0.25 $0.35 20.00% 6.50% 6.00% 1.00% 33.50% $0.12 $0.47 $0.4715D Turbine Wheel 1201-N0101-01-01-24-0212 Plane Dynamic Balance T2/T3 CNC Turning, MSMC NotApplicable Precision Assembly Balancing, SMS, MHC180 4.5 3 10.000$0.00 $25.74 $45.00 $135.00$0.00$0.64 $0.75 $1.39 20.00% 6.50% 6.00% 1.00% 33.50% $0.47 $1.86 $1.8616A Turnbine Shaft 1201-N0101-01-01-24-03-011Machine & Grind Shaft T2/T3 CNC Turning, MSMCA-Steel-4140, BarCNC Operator S-CNC Turning, MC176 1 2.5 10.255$0.78 $35.70 $55.00 $137.50 $0.20 $0.20 $0.78 $1.18 10.00% 6.50% 6.00% 1.00% 23.50% $0.28 $1.46 $1.469,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includesImpeller Wheels, 5%Casting fallout, 10%Wheel BalanceFallout and 10% FinalAssembly BalanceFalloutFile:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APPENDIX G.1-15, 2 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Turbo Assembly 1501 Rev 5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(1of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Turbo Charging AssemblyPart Number:1501-N0101-01Weekly Component Volume: Packaging Specification:ReturnableComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includes16B Turnbine Shaft 1201-N0101-01-01-24-031Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC250 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.40 $0.59 10.00% 6.50% 6.00% 1.00% 23.50% $0.14 $0.72 $0.72Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Seal Shaft exhaust end 1201-N0101-01-251(M2 Tool Steel & Inconel) S$0.00$1.00$0.00 $1.002A Plug Threaded 1201-N0101-01-30-032S$0.00$0.04$0.00 $0.083A Sleeve Shaft Bushing 1201-N0101-01-30-021S$0.00$0.03$0.00 $0.034A Snap Ring - Bearing retainer 1201-N0101-01-311S$0.00$0.02$0.00 $0.025a C-Clip - Bushing Retainer 1201-N0101-01-331S$0.00$0.01$0.00 $0.016A O-Ring Inner ID of support plate to block 1201-N0101-01-211S$0.00$0.18$0.00 $0.187A Spacer Oil Diverter Plates 1201-N0101-01-201S$0.00$0.06$0.00 $0.068A Seal - Shaft Support Plate to seal carrier 1201-N0101-01-281S$0.00$0.02$0.00 $0.029A Nut turbine Shaft 1201-N0101-01-151S$0.00$0.08$0.00 $0.0810A O-Ring Intake Housing to block seal 1201-N0101-01-141S$0.00$0.08$0.00 $0.0811A Bolt Intake Housing to Shaft Housing 1201-N0101-01-044S$0.00$0.07$0.00 $0.3012A Pin Housing to Center Block Locating 1201-N0101-01-09-01-131S$0.00$0.01$0.00 $0.0113A Bushing Dump Valve Shaft 1201-N0101-01-09-01-091(Specialized Alloy or Nitrided) S$0.00$0.86$0.00 $0.8614A Washer - Valve Retainer 1201-N0101-01-09-01-071Stainless S$0.00$0.17$0.00 $0.1715A Washer Block retainer 1201-N0101-01-09-01-111Steel S$0.00$0.03$0.00 $0.0316A Stud Turbo to Exhaust Manifold 1201-N0101-01-114Stainless (A286) S$0.00$0.27$0.00 $1.0717A Stud - Catalytic Coverter 1280-N0101-073Stainless (A286) S$0.00$0.37$0.00 $1.1018A Clamp Exhaust housing to shaft block 1201-N0101-01-081Stainless S$0.00$1.24$0.00 $1.2419A Nut Saddle Clamp 1201-N0101-01-131Stainless S$0.00$0.03$0.00 $0.0320A Solenoid Intake Bypass 1201-N0101-01-051S$0.00$6.00$0.00 $6.0021A Gasket Intake Housing Solenoid 1201-N0101-01-121S$0.00$0.08$0.00 $0.0822A Bolt Solenoid to Intake Housing 1201-N0101-01-063S$0.00$0.06$0.00 $0.1823A Diaphram Exhaust dump valve 1201-N0101-01-011S$0.00$5.00$0.00 $5.0024A Nut Exhaust Diaphram Shaft 1201-N0101-01-022S$0.00$0.01$0.00 $0.0125A Nut Diaphram to Intake Housing 1201-N0101-01-032S$0.00$0.01$0.00 $0.0226A Gasket - Turbo Inlet to Exhaust Manifold 1285-N0101-011S$0.00$1.60$0.00 $1.6027A Nut - Turbo to exhaust Manifold 1280-N0101-104S$0.00$0.09$0.00 $0.3528A Tag ID 1201-N0101-01-07-021S$0.00$0.10$0.00 $0.1029A Rivet ID Tag 1201-N0101-01-07-031S$0.00$0.01$0.00 $0.010$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$126.77T1 or OEM Total Manufacturing Cost:$49.30 $26.79 $33.75 $109.84 $5.45 $5.38 $5.15 $0.94 $16.93$126.77T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.89 $8.87 $10.14 $5.07 $24.97Base Cost Impact to Vehicle:$49.30 $26.79 $33.75 $109.84 $6.34 $14.26 $15.29 $6.01 $41.90 $151.75 $0 $0Packaging Cost:$0.11Net Cost Impact to Vehicle:$151.85Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.108 $215,4260.00%2,250,000 605.00%$30071880657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.108PACKAGING CALCULATIONS:Packaging Type: Option #2Part Size: 300x200X190Parts/Layer: 4x5Number of Layers: 4"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APPENDIX G.1-15, 3 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Cooler Assembly 1505Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(2of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cooler Assembly - Charged AirPart Number:1505-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1B Tube with cooling fins 1505-N0101-01-1-15Insert Cooling Fins, Laserweld seem on Tube, PressureTest.S Not Applicable General Assembly Mech. Assembly, MC566 20.000$0.00 $35.51 $125.19$0.00$0.13 $0.22 $0.350.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.35 $1.732C Cooler Assembly - Charged Air Heat Exchanger 1505-N0101-01-01-021Assemble Tube Assemblies,Outer Fins, Top/Bottom Platesand Header Plates, Gasket &End CapsS Not Applicable General Assembly Mech. Assembly, MC116 50.000$0.00 $35.51 $125.19$0.00$1.53 $1.08 $2.610.00% 0.00% 0.00% 0.00%0.00% $0.00 $2.61 $2.61Purchase Part - High Impact Item (Full Cost Mapping)1A Tube1505-N0101-01-1-25Pre-Form & Cut to Length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC514 0.50.320$1.65 $42.18 $125.10 $0.53 $0.04 $0.24 $0.810.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.81 $4.062A Cooling Fins Inside Tube 1505-N0101-01-1-3-015Form and Cut to Length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC720 0.50.100$1.65 $42.18 $125.10 $0.17 $0.03 $0.17 $0.370.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.37 $1.843A Top/Bottom Plates 1505-N0101-01-1-42Form and Cut to Length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC720 0.50.110$1.65 $42.18 $125.10 $0.18 $0.03 $0.17 $0.380.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.38 $0.774A Cooling Fins Outer 1505-N0101-01-1-5--016Lance, Form, Cut to length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC720 0.50.140$1.65 $42.18 $125.10 $0.23 $0.03 $0.17 $0.430.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.43 $2.604B Header Plate 1505-N0101-01-1-6-012Pierce and Form SAluminum3003/4047B,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC529 0.250.130$2.10 $42.18 $125.10 $0.27 $0.02 $0.24 $0.530.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.53 $1.065AEnd Cap R Cooler Assembly - Charged Air HeatExchange1505-N0101-01-21Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS655 0.50.254$1.54 $43.52 $100.01 $0.39 $0.03 $0.15 $0.580.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.58 $0.585BEnd Cap L Cooler Assembly - Charged Air HeatExchange1505-N0101-01-31Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS643 0.50.299$1.54 $43.52 $100.01 $0.46 $0.03 $0.16 $0.650.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.65 $0.65Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchase Price/UnitPurchase PriceNet, PIAPurchase PriceNet, End Item1A Gasket End Cap 1505-N0101-01-42S$0.00$0.15$0.00 $0.300$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$16.20T1 or OEM Total Manufacturing Cost:$6.91 $2.85 $6.44 $16.20 $0.00 $0.00 $0.00 $0.00 $0.00 $16.20T1 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 $2.35Base Cost Impact to Vehicle:$6.91 $2.85 $6.44 $16.20 $0.08 $0.97 $0.97 $0.32 $2.35 $18.55 $0 $0Packaging Cost:$0.10Net Cost Impact to Vehicle:$18.65109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 4 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Cooler Assembly 1505Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(2of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cooler Assembly - Charged AirPart Number:1505-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.096 $382,9790.00%4,500,000 605.00%$42091263657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.096File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 5 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y-Waste Gate 1570AManufacturing Assumption and Quote SummaryAPPENDIX G.1-15(3of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly - Turbo Waste Gate Pneumatic ControlPart Number:1570-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube Reservoir to Solenoid 1770-N0101-03-11Assemble sheathing and glueon end connections.S Not Applicable General Assembly Mech. Assembly, LC180 10.000$0.00 $35.51 $100.19$0.00$0.20 $0.56 $0.750.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.75 $0.752A Tube Reservoir to Pump 1770-N0101-03-21Assemble sheathing and glueon end connections.S Not Applicable General Assembly Mech. Assembly, LC157 10.000$0.00 $35.51 $100.19$0.00$0.23 $0.64 $0.870.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.87 $0.873A Tube - Sol to Wastegate 1770-N0101-03-41Assemble sheathing S Not Applicable General Assembly Mech. Assembly, LC300 10.000$0.00 $35.51 $100.19$0.00$0.12 $0.33 $0.450.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.45 $0.45Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Reservoir to Solenoid 1770-N0101-03-1-11Extrude and Form S Nylon12, Inject. Extruding/DrawingOperator Comp./Ext. Mold, LMC400 1.50.009$3.03 $54.35 $100.04 $0.03 $0.20 $0.25 $0.480.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.48 $0.482A Tube Preformed 1770-N0101-03-2-11Extrude and Form S Nylon12, Inject. Extruding/DrawingOperator Comp./Ext. Mold, LMC257 1.50.020$3.03 $54.35 $100.04 $0.06 $0.32 $0.39 $0.770.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.77 $0.773A Tube - Sol to Wastegate 1770-N0101-03-4-11Extrude S Thermoset-SBR Extruding/Drawing Operator Comp./Ext. Mold, LMC514 0.50.095$1.32 $54.35 $100.04 $0.13 $0.05 $0.19 $0.370.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.37 $0.37Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hose Tube end connections 1770-N0101-03-1-24Rubber S$0.00$0.04$0.00 $0.162A Sheath Tube-Short 1770-N0101-03-1-31Nylon S$0.00$0.20$0.00 $0.203A Sheath Tube - medium 1770-N0101-03-2-21Nylon S$0.00$0.50$0.00 $0.504A Sheath Tube-Long 1770-N0101-03-4-21Nylon S$0.00$0.60$0.00 $0.605A Zip Tie - tube to tube 1770-N0101-03-33S$0.00$0.02$0.00 $0.066A Zip Tie Edge Bitter - tube to tube 1770-N0101-03-61S$0.00$0.12$0.00 $0.127A Isolator/Hose wrap 1770-N0101-03-51S$0.00$0.08$0.00 $0.08Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$5.41T1 or OEM Total Manufacturing Cost:$1.93 $1.12 $2.36 $5.41 $0.00 $0.00 $0.00 $0.00 $0.00 $5.41T1 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 $0.61Base Cost Impact to Vehicle:$1.93 $1.12 $2.36 $5.41 $0.02 $0.32 $0.22 $0.05 $0.61 $6.03 $0 $0Packaging Cost:$0.10Net Cost Impact to Vehicle:$6.12Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.013 $26,5960.00%2,250,000 605.00%$200133432657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.09$1.00 10 $3.00 9 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.099109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging Option #1 with expendabledividers.12 Cells per Layer, 4 parts per Cell.9 Layers.Total # of Parts/Pallet =432"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 6 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Assembly-Inlet 1570BManufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (4of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Ass'y w. Vehicle Tie Down Canister, Air CoolerInletPart Number:1570-N0101-20/21/22Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Resonator Tube Sub-Assembly 1570-N0101-211Spin Weld Housing Inner toBaffle InnerS Not Applicable General Assembly Mech. Assembly, LC300 30.000$0.00 $35.51 $100.19$0.00$0.36 $0.33 $0.690.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.69 $0.692ATube Ass'y w. Vehicle Tie Down Canister, AirCooler1570-N0101-191Assembly Tubes to Resonator S Not Applicable General Assembly Mech. Assembly, LC200 30.000$0.00 $35.51 $100.19$0.00$0.53 $0.50 $1.030.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.03 $1.03Purchase Part - High Impact Item (Full Cost Mapping)1A Hose Long 1570-N0101-19-21Extrude and Form SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC295 1.50.691$1.85 $54.35 $100.04 $1.28 $0.28 $0.34 $1.890.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.89 $1.891B Hose Long w. Overmold Clamp 1570-N0101-19-21Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.642A Hose Short Preformed 1570-N0101-19-61Extrude and Form SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC450 1.50.387$1.85 $54.35 $100.04 $0.71 $0.18 $0.22 $1.120.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.12 $1.123A Housing Outer Shell 1570-N0101-19-4-11Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS554 0.250.513$1.54 $43.52 $100.01 $0.79 $0.02 $0.18 $0.990.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.99 $0.993B Baffle Inner Tube & End Cap 1570-N0101-19-4-21Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS610 0.250.203$1.54 $43.52 $100.01 $0.31 $0.02 $0.16 $0.490.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.49 $0.49Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hose Clamp 1570-N0101-19-332" S$0.00$0.27$0.00 $0.812A Sleeve Tube Anti-Crush 1570-N0101-19-4-32Steel, Nickel/Zinc Plate S$0.00$0.30$0.00 $0.603A Hose clamp 1570-N0101-19-812" w. Retention Teeth S$0.00$0.35$0.00 $0.354A Grommet Fastener Isolator 1570-N0101-19-4-41S$0.00$0.08$0.00 $0.085A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-51S$0.00$0.05$0.00 $0.05Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$8.75T1 or OEM Total Manufacturing Cost:$4.98 $1.61 $2.16 $8.75 $0.00 $0.00 $0.00 $0.00 $0.00 $8.75T1 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 $0.99Base Cost Impact to Vehicle:$4.98 $1.61 $2.16 $8.75 $0.03 $0.53 $0.35 $0.09 $0.99 $9.74 $0 $0Packaging Cost:$0.08Net Cost Impact to Vehicle:$9.82Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.030 $59,8400.00%2,250,000 605.00%$200299192657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.05$1.00 9 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.077109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTOption #1 with Tier Pad DividersPart Size =600x180x110Parts per Pallet = 2 Rows of 12, 8layers= 192 parts"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 7 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Assembly-Outlet-1570CManufacturing Assumption and Quote SummaryAPPENDIX G.1-15(5of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Ass'y w. Vehicle Tie Down Canister, Air CoolerOutletPart Number:1570-N0101-30Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube 1570-N0101-30-51Install Inserts and Grommets S Not Applicable GeneralAssembly Mech. Assembly, LC240 50.000$0.00 $35.51 $100.19$0.00$0.74 $0.42 $1.160.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.16 $1.162 Tube - Charge Air Cooler Outlet 1570-N0101-301Install Hose, Clamp S Not Applicable General Assembly Mech. Assembly, LC180 20.000$0.00 $35.51 $100.19$0.00$0.39 $0.56 $0.950.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.95 $0.95Purchase Part - High Impact Item (Full Cost Mapping)1A Tube 1570-N0101-30-51Friction Weld S Not Applicable Mold/Cast/Sinter Operator Inject. Mold, SMS180 30.000$0.00 $43.52 $100.01$0.00$0.73 $0.56 $1.280.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.28 $1.281B Tube 1570-N0101-30-5-21Extrude & Blow Form Tube S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS145 11.612$1.59 $43.52 $100.01 $2.56 $0.30 $0.69 $3.550.00% 0.00% 0.00% 0.00%0.00% $0.00 $3.55 $3.552A Tube Attachment #1 1570-N0101-30-5-311Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.250.015$1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.18 $0.183A Tube Attachment #2 1570-N0101-30-5-321Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.250.015$1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.18 $0.184A Tube Attachment #3 1570-N0101-30-5-331Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.250.015$1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.18 $0.185A Hose preformed 1570-N0101-30-31Extrude and Form SSBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC367 1.50.676$1.85 $54.35 $100.04 $1.25 $0.22 $0.27 $1.740.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.74 $1.745B Hose w/Clamps 1570-N0101-30-11Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.64Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Insert Brass Threaded 1570-N0101-30-61S$0.00$0.04$0.00 $0.042A Sleeve Tube Anti-Crush 1570-N0101-19-4-32S$0.00$0.30$0.00 $0.603A Grommet Fastener Isolator 1570-N0101-19-4-41S$0.00$0.08$0.00 $0.084A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-51S$0.00$0.05$0.00 $0.055A Nut - Flag w/Isolator 1570-N0101-30-71S$0.00$0.25$0.00 $0.256A Sleeve Anti Crush 1570-N0101-30-81S$0.00$0.30$0.00 $0.307A Hose Clamp 1570-N0101-30-42S$0.00$0.29$0.00 $0.588ASensor - Intake Temperature, Outlet Charged Air Co1599-N0101-031S$0.00$5.00$0.00 $5.009A Bolt - Sensor, Charge Air Temperature 1580-N0101-101S$0.00$0.04$0.00 $0.04Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$16.81T1 or OEM Total Manufacturing Cost:$10.83 $2.65 $3.32 $16.81 $0.00 $0.00 $0.00 $0.00 $0.00 $16.81T1 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 $1.90Base Cost Impact to Vehicle:$10.83 $2.65 $3.32 $16.81 $0.05 $1.01 $0.67 $0.17 $1.90 $18.70 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$18.76Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.057 $227,3940.00%4,500,000 605.00%$38059896657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.057109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPallet Option #2,Part Size = 600x150x140Parts per Pallet = 2 Rows, 8 per row, 6Layers = 96 Parts per Pallet"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 8 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Assembly-Outlet-1570DManufacturing Assumption and Quote SummaryAPPENDIX G.1-15(6of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube - Elbow, Upper to Charged Air Coupler By-PassPart Number:1570-N0101-40Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Tube - Elbow, Upper to Charged Air Coupler ByPas1570-N0101-401Crimp End Hose Piece ontoHose and Add O-RingS Not Applicable General Assembly Mech. Assembly, LC240 10.000$0.00 $35.51 $100.19$0.00$0.15 $0.42 $0.570.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.57 $0.57Purchase Part - High Impact Item (Full Cost Mapping)1A Tube (Hose) preformed 1570-N0101-40-11Extrude and Form SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC400 1.50.620$1.85 $54.35 $100.04 $1.15 $0.20 $0.25 $1.600.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.60 $1.601B Tube (Hose) w/Clamps 1570-N0101-40-1-11Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.64Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemHose Clamp 1570-N0101-40-21S$0.00$0.25$0.00 $0.25Hose end piece 1570-N0101-40-31S$0.00$0.75$0.00 $0.75O-ring Seal Tube OD 1570-N0101-40-41S$0.00$0.11$0.00 $0.110$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.92T1 or OEM Total Manufacturing Cost:$2.26 $0.58 $1.08 $3.92 $0.00 $0.00 $0.00 $0.00 $0.00 $3.92T1 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 $0.44Base Cost Impact to Vehicle:$2.26 $0.58 $1.08 $3.92 $0.01 $0.24 $0.16 $0.04 $0.44 $4.36 $0 $0Packaging Cost:$0.03Net Cost Impact to Vehicle:$4.39Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.010 $19,9470.00%2,250,000 605.00%$200100576657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.02$1.00 10 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.027109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackage Option #1Part Size = 200x140x90mmEach Layer = 4 rows of 16Number of Layers = 9Total Parts per Pallet = 576"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 9 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Inlet ETB-1570Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (7of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Part Number:1570-N0101-41/42/43/44Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Flex Tube Silencer to Environment1070-N0101-05-3(1570-N0101-44)1Heat Stake Cap to Flex Tubeand add foam.S Not Applicable General Assembly Mech. Assembly, LC240 10.000$0.00 $35.51 $100.19$0.00$0.15 $0.42 $0.570.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.57 $0.572A Silencer - Charge Air By-Pass1070-N0101-05-2(1599-N0101-04)1Insert Inner Baffle andVibration Weld HousingS Not Applicable General Assembly Mech. Assembly, LC240 10.000$0.00 $35.51 $100.19$0.00$0.15 $0.42 $0.570.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.57 $0.573AHose Ass'y Silencer to Y Couple(Tube - Charged Air Bypass to Silencer)1070-N0101-05-5(1570-N0101-43)1Assemble Protective Sheathand IsolatorS Not Applicable General Assembly Mech. Assembly, LC300 10.000$0.00 $35.51 $100.19$0.00$0.12 $0.33 $0.450.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.45 $0.454A Tube Inlet to throttle body1070-N0101-05(1570-N0101-42)1Assemble Individual TubeAssemblies with clampsS Not Applicable General Assembly Mech. Assembly, LC120 40.000$0.00 $35.51 $100.19$0.00$1.18 $0.83 $2.020.00% 0.00% 0.00% 0.00%0.00% $0.00 $2.02 $2.02Purchase Part - High Impact Item (Full Cost Mapping)1A Tube - Flex Elbow, Silencer to Environment1070-N0101-05-15-1(1570-N0101-44)1Injection Mold S TPE-PP/EPDM, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS710 10.205$0.99 $43.52 $100.01 $0.20 $0.06 $0.14 $0.410.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.41 $0.412ATube - Flex Elbow, Silencer to Environment,Snap1070-N0101-05-15-2(1570-N0101-44)1Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.50.020$1.59 $43.52 $100.01 $0.03 $0.03 $0.14 $0.200.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.20 $0.203A Silencer Outer Shell 1070-N0101-05-2-11Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS509 0.50.270$1.45 $43.52 $100.01 $0.39 $0.04 $0.20 $0.630.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.63 $0.634A Silencer Inner Baffle 1070-N0101-05-2-1-2-31Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS986 0.50.140$1.45 $43.52 $100.01 $0.20 $0.02 $0.10 $0.330.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.33 $0.335A Silencer End Cap 1070-N0101-05-2-1-21Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS900 0.50.140$1.45 $43.52 $100.01 $0.20 $0.02 $0.11 $0.340.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.34 $0.346A Tube (Hose) preformed 1570-N0101-40-11Extrude and Form SSBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC383 1.50.380$1.85 $54.35 $100.04 $0.70 $0.21 $0.26 $1.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.18 $1.187A Tube Y-Coupler to bypass1070-N0101-05-8-1(1570-N0101-41)1Injection Mold S Nylon6-30GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS923 0.50.289$1.76 $43.52 $100.01 $0.51 $0.02 $0.11 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.648AElbow Coupler Bypass to Throttle(Tube-Elbow Coupler By-Pass to Throttle Body)1070-N0101-05-10-1(1570-N0101-42)1Extrude and Form SSBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC343 1.50.723$1.85 $54.35 $100.04 $1.34 $0.24 $0.29 $1.870.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.87 $1.878BElbow Coupler Bypass to Throttle w. Clamp(Tube-Elbow Coupler By-Pass to Throttle Body)1070-N0101-05-11(1570-N0101-42)1Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.64Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchase PriceNet, PIAPurchase PriceNet, End Item1A Seal foam press in place tape style 1070-N0101-05-161S$0.00$0.10$0.00 $0.102A Grommet - Silencer to Engine 1070-N0101-05-991S$0.00$0.15$0.00 $0.153A Sheath Hose Protection 1070-N0101-05-141S$0.00$0.38$0.00 $0.384A Isolator Hose 1070-N0101-05-71S$0.00$0.12$0.00 $0.125A Hose Clamp lrg end molded in place 1070-N0101-05-121S$0.00$0.40$0.00 $0.406a Hose Clamp sml end 1070-N0101-05-111S$0.00$0.27$0.00 $0.277a Hose Clamp 1070-N0101-05-43S$0.00$0.16$0.00 $0.480$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$11.73T1 or OEM Total Manufacturing Cost:$5.48 $2.48 $3.77 $11.73 $0.00 $0.00 $0.00 $0.00 $0.00 $11.73T1 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 $1.33Base Cost Impact to Vehicle:$5.48 $2.48 $3.77 $11.73 $0.04 $0.70 $0.47 $0.12 $1.33 $13.05 $0 $0Packaging Cost:$0.07Net Cost Impact to Vehicle:$13.1247450,0001450,000North AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsMARK-UP COSTSGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTube: 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 EnvironmentTOTAL COSTSTOOLING & INVESTMENT109,574"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 10 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Inlet ETB-1570Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (7of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Part Number:1570-N0101-41/42/43/44Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "47450,0001450,000North AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsMARK-UP COSTSGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTube: 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 EnvironmentTOTAL COSTSTOOLING & INVESTMENT109,574Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.066 $131,6490.00%2,250,000 605.00%$22059896657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.066Pallet Options: Option #1 No Tier Pads, 8Cell Returnable Pallet DividersPart Size: 600x300x100Parts/Layer = 2x4 = 8Number of Layers = 12File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 11 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Bracket-Support Turbo 1575Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(8of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bracket - Support, Turbo AssemblyPart Number:1575-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Bracket - Support, Turbo Assembly1575-N0101-01(1275-N0101-04)1Forging S S-Steel-304, Bar Forging Operator Cold Forge,LMC257 10.649$1.65 $38.52 $100.09 $1.07 $0.15 $0.39 $1.610.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.61 $1.61Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.61T1 or OEM Total Manufacturing Cost:$1.07 $0.15 $0.39 $1.61 $0.00 $0.00 $0.00 $0.00 $0.00 $1.61T1 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 $0.17Base Cost Impact to Vehicle:$1.07 $0.15 $0.39 $1.61 $0.00 $0.10 $0.06 $0.00 $0.17 $1.78 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$1.84Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.001 $1,5960.00%2,250,000 605.00%$100163600657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.06$0.00 0 $0.00 0 $3.50 60 $0.00 0 $0.00 0Packaging Cost Total:$0.059109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaged in Expendible Card BoardBoxes(Weight Consideration<40lbs)Card Board Box: 300x220x120($3.50/Box)Parts per Box: 15 per layer x 4Layers/Box = 60 Parts/BoxPer Pallet (1/2 Pallet), 4x5 Boxes perlayer3 layers = 60 Boxes"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 12 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Vac. Reservoir 1599Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(9of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Vacuum Reservoir - Turbo Waste GatePart Number:1599-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Vacuum Reservoir7070-N0101-02(1599-N01010-01)1Vibration Weld and AssemblyInsertsS Not Applicable General Assembly Mech. Assembly, LC240 20.000$0.00 $35.51 $100.19$0.00$0.30 $0.42 $0.710.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.71 $0.71Purchase Part - High Impact Item (Full Cost Mapping)1A Cover - cap: Vacuum Reservoir 7070-N0101-02-11PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS1037 0.50.158$1.76 $43.52 $100.01 $0.28 $0.02 $0.10 $0.400.30% 6.00% 4.00% 0.00%10.30% $0.04 $0.44 $0.442A Base Reservoir: Vacuum Reservoir 7070-N0101-02-21PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS861 0.50.454$1.76 $43.52 $100.01 $0.80 $0.03 $0.12 $0.940.30% 6.00% 4.00% 0.00%10.30% $0.10 $1.04 $1.04Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Anti-Crush Sleeves Vacuum Reservoir 7070-N0101-02-33$0.00$0.04$0.12 $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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$2.19T1 or OEM Total Manufacturing Cost:$1.08 $0.34 $0.63 $2.05 $0.00 $0.08 $0.05 $0.00 $0.14 $2.19T1 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 $0.34Base Cost Impact to Vehicle:$1.08 $0.34 $0.63 $2.05 $0.01 $0.22 $0.18 $0.05 $0.48 $2.53 $0 $0Packaging Cost:$0.10Net Cost Impact to Vehicle:$2.63Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.017 $33,4970.00%2,250,000 605.00%$200167343657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.08$1.00 8 $3.00 7 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.101109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPallet Option #1 w. Disposable TierPadsPart Size:170x150x115Parts Layer = 7x7 =49Number of Layers = 7"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 13 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Valve-Thrust Control 1599Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (10of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Value - Thrust Control, Turbo Waste Gate PneumaticControlPart Number:1599-N0101-02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1AValue - Thrust Control, Turbo Waste GatePneumatic Control1599-N0101-021(Look @ Evaluating as LowImpact Supplier)S$0.00$5.19$0.00 $5.190$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$5.19T1 or OEM Total Manufacturing Cost:$5.19 $0.00 $0.00 $5.19 $0.00 $0.00 $0.00 $0.00 $0.00 $5.19T1 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 $0.80Base Cost Impact to Vehicle:$5.19 $0.00 $0.00 $5.19 $0.03 $0.34 $0.31 $0.13 $0.80 $5.99 $0 $0Packaging Cost:$0.02Net Cost Impact to Vehicle:$6.02Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.024 $48,9800.00%2,250,000 605.00%$4,420115184657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.024109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging Option #3 w. ReturnableTraysPart Size 80x90x50Parts/Layer = 6x3 = 18Number of Layers = 6"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 14 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1500Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (11of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Vehicle AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine And Vehicle AssemblyPart Number:1500-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Turbo Charging Assembly 1501-N0101-011Mount Turbo Assembly toIntake Manifold, 4 NutsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM82 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.02 $1.53 $2.55 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.55 $2.552A Bracket - Support, Turbo Assembly 1575-N0101-011Install Turbo Support Bracket, 2BoltsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM97 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.86 $1.29 $2.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.14 $2.143A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-011Install Vacuum Reservoir, 2Bolts and 1 NutOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM90 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.93 $1.39 $2.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.32 $2.324AValue - Thrust Control, Turbo Waste GatePneumatic Control1599-N0101-021Install Valve to Mount Bracket,No Additional FastenerOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM240 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.35 $0.52 $0.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.87 $0.875ATube Assembly - Turbo Waste Gate PneumaticControl1570-N0101-031Install Waste Gate Tubing, 6Attachment PointsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM73 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.13 $1.70 $2.84 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.84 $2.846A Cooler Assembly - Charged Air 1505-N0101-011Install Vehicle H/W for ChargedAir Cooler and Charged AirCooler.OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM49 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.71 $2.57 $4.29 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.29 $4.297ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Inlet1570-N0101-20/21/221Install Tube Assembly, TurboAssembly to Charged AirCoolerOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM75 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.11 $1.67 $2.78 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.78 $2.788ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Outlet1570-N0101-301Install Tube Assembly,Charged Air Cooler toCoupler/ETB bypassOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM61 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.37 $2.05 $3.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.42 $3.429ATube - Elbow, Upper to Charged Air Coupler By-Pass1570-N0101-401Make Connection BetweenCharged Air Outlet Tube andElectronic Throttle Body InletTube.OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM189 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.44 $0.66 $1.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.10 $1.1010ATube: Coupler Y Branch to By-Pass/ElbowCoupler By-Pass to Throttle Body/ElbowCoupler By-Pass to Throttle Body/Tube - FlexElbow, Silencer to Environment1570-N0101-41/42/43/441Make Connection to ThrottleBody and Snap in Bypass Tubeto Vehicle BodyOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM92 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.90 $1.36 $2.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.26 $2.26Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Turbo Charging Assembly 1501-N0101-011SAC$151.85$151.85$0.00 $151.852A Bracket - Support, Turbo Assembly 1575-N0101-011SAC$1.84$1.84$0.00 $1.843A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-011SAC$2.63$2.63$0.00 $2.634AValue - Thrust Control, Turbo Waste GatePneumatic Control1599-N0101-021SAC$6.02$6.02$0.00 $6.025ATube Assembly - Turbo Waste Gate Pneumatic Control1570-N0101-031SAC$6.12$6.12$0.00 $6.126A Cooler Assembly - Charged Air 1505-N0101-011SAC$18.65$18.65$0.00 $18.657ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Inlet1570-N0101-20/21/221SAC$9.82$9.82$0.00 $9.828ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Outlet1570-N0101-301SAC$18.76$18.76$0.00 $18.769ATube - Elbow, Upper to Charged Air Coupler By-Pass1570-N0101-401SAC$4.39$4.39$0.00 $4.3910ATube: Coupler Y Branch to By-Pass/ElbowCoupler By-Pass to Throttle Body/ElbowCoupler By-Pass to Throttle Body/Tube - FlexElbow, Silencer to Environment1570-N0101-41/42/43/441SAC$0.00$0.00$0.00 $0.0011A Nut - Exhaust Manifold to Turbo 1280-N0101-074S$0.00$0.14$0.00 $0.5712A Bolt - Bracket Support, Turbo Assembly 1580-N0101-031S$0.00$0.05$0.00 $0.0513A Bolt - Bracket Support, Turbo Assembly 1580-N0101-041S$0.00$0.04$0.00 $0.0414A Bolt - Pressure Reservoir, Turbo Waste Gate 1580-N0101-052S$0.00$0.05$0.00 $0.0915A Nut - Pressure Reservoir, Turbo Waste Gate 1580-N0101-061S$0.00$0.01$0.00 $0.0116A Bolt - Tube, Charge Air Cooler to Vehicle 1580-N0101-092Hardware Not Available S$0.00$0.04$0.00 $0.0717A Internal Threaded Part ( Vehicle H/W) NA2Hardware Not Available S$0.00$0.03$0.00 $0.0518A Isolators Veh. Mnt. Charged Air Cooler NA2S$0.00$0.08$0.00 $0.1619ABolt - Tube Ass'y w. Vehicle Canister Tie Down....NA1Hardware Not Available S$0.00$0.01$0.00 $0.019,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingforboth Technology Packages)File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 15 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1500Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (11of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Vehicle AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine And Vehicle AssemblyPart Number:1500-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includes costingforboth Technology Packages)20AInternal Threaded Part ( Vehicle H/W Inlet (1 pc)& Outlet (2 pcs) Air Tube Canister Tie Down)NA3Hardware Not Available S$0.00$0.02$0.00 $0.0521A Bolt - Tube Charged Air Cooler Outlet NA2Hardware Not Available S$0.00$0.01$0.00 $0.0222A Screw Tube Intake Manifold to Attachment NA1Hardware Not Available S$0.00$0.01$0.00 $0.01Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$245.77T1 or OEM Total Manufacturing Cost:$221.21 $9.81 $14.75 $245.77 $0.00 $0.00 $0.00 $0.00 $0.00 $245.77T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(220.07)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.14 $9.81 $14.75 $25.70 $0.00 $0.00 $0.00 $0.00 $0.00 $25.70 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$25.70Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:No Packaging Considerations Required. PackagingCosts for fasteners (bolts, nuts, etc.) is capturedin thepiece costs.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 16 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 17Breather SubsystemCase Study #0101MAQS WorksheetsFile:Breather Subsystem 17 040209.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-17, 1 of 2Oil-Air Separator 1702Manufacturing Assumption and Quote SummaryAPPENDIX G.1-17 (1of1)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Oil/Air SeparatorPart Number:1702-N0101-00Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Oil/Air Separator 1702-N0101-001Final Assembly of PCV systemto cover.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base257 1 1 30.000$0.00 $35.51 $15.00 $45.00$0.00$0.14 $0.18 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.310##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1AValve - Non Return Intake Hose & Manifold Side1702-N0101-01/41-012Injection Mold Flap withovermold HingeT2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS720 1 1 10.005$1.54 $43.52 $100.01 $100.01 $0.01 $0.06 $0.14 $0.21 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.24 $0.471BValve - Non Return Intake Hose & Manifold Side1702-N0101-01/41-022Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS800 0 1 10.002$1.27 $43.52 $100.01 $100.01 $0.00$0.00$0.13 $0.13 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.15 $0.292A Separator - Cyclone 1702-N0101-101Injection Mold (AdditionalPlastic added to Mini Coverover GEMA cover)T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS545 0 1 10.818$1.54 $43.52 $150.01 $150.01 $1.26$0.00$0.28 $1.53 0.50% 6.50% 6.00% 1.00% 14.00% $0.21 $1.75 $1.753AValve - Pressure Control1702-N0101-201Nylon Injection Mold T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS391 1 1 10.005$1.54 $43.52 $100.01 $100.01 $0.01 $0.11 $0.26 $0.37 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.43 $0.433BValve - Pressure Control1702-N0101-201Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS389 0 1 10.002$1.27 $43.52 $100.01 $100.01 $0.00$0.00$0.26 $0.26 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30 $0.300##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hinge Flow control flap 1702-N0101-802S$0.00$0.03$0.00 $0.060$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.61T1 or OEM Total Manufacturing Cost:$1.35 $0.37 $1.49 $3.21 $0.01 $0.18 $0.17 $0.03 $0.40 $3.61T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.02 $0.23 $0.22 $0.09 $0.56Base Cost Impact to Vehicle:$1.35 $0.37 $1.49 $3.21 $0.03 $0.42 $0.39 $0.12 $0.96 $4.17 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$4.17Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:No Packaging Impact"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Breather Subsystem 17 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-17, 2 of 2Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 60Engine Management, EngineElectronic, and ElectricalSubsystemsCase Study #0101MAQS WorksheetsFile:Electrical Subsystem 6000 040209.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-60, 1 of 5PCM HW 6002AManufacturing Assumption and Quote SummaryAPPENDIX G.1-60, (1of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Power Train Control Module (PCM) Assembly - HardwarePart Number:0602-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1APower Train Control Module (PCM) Assembly -Hardware0602-N0101-011The PCM H/W is carry overexcept for the PFI drivers. GDIdrivers use a 75-80VDC BoostCircuit and 25A Peak/HoldDrivers.The turbo is just another lowside driver really no cost.S$0.00$40.00$0.00 $40.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$40.00T1 or OEM Total Manufacturing Cost:$40.00 $0.00 $0.00 $40.00 $0.00 $0.00 $0.00 $0.00 $0.00 $40.00T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$40.00 $0.00 $0.00 $40.00 $0.00 $0.00 $0.00 $0.00 $0.00 $40.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$40.00Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:NAPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 2 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411PCM SW 6002BManufacturing Assumption and Quote SummaryAPPENDIX G.1-60, (2of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Power Train Control Module (PCM) Assembly - SoftwarePart Number:6002-N0101-50Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1APower Train Control Module (PCM) Assembly -Software6002-N0101-501• Control system is much morecomplicated in order to controlinjection timing, split injections,fuel rail pressure, electric waterpump, electric thermostat, etc.S$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$0.00T1 or OEM Total Manufacturing Cost:$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.00Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:NAPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includes costingfor both Technology Packages)Per discussion with BrianNelson, Software will be coveredby indirect cost multiplier.5/20/09File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 3 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411Electrical 6003Manufacturing Assumption and Quote SummaryAPPENDIX G.1-60 (3of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)Part Number:6003-N0101-01/30Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Wire Turbo Connector 0603-N0101-302($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.002A Wire Coolant Aux Pump 0603-N0101-303($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.503A Clip Harness Retention2S$0.00$0.01$0.00 $0.024A Wire Waste Gate Sol 0603-N0101-302($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.005A Wire Charge Air Temp 0603-N0101-304($0.50/Wire Circuit) S$0.00$0.50$0.00 $2.006A Clip Harness Retention1S$0.00$0.01$0.00 $0.017A Edge Biter Harness Retention3S$0.00$0.02$0.00 $0.068A Wire HP Fuel Pump Control2($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.009A Wire Fuel Pressure Sensor 0603-N0101-303($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.5010A Ignition Coil Assembly - Single Spark 0603-N0101-014S$0.00$1.01$0.00 $4.04$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$12.13T1 or OEM Total Manufacturing Cost:$12.13 $0.00 $0.00 $12.13 $0.00 $0.00 $0.00 $0.00 $0.00 $12.13T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$12.13 $0.00 $0.00 $12.13 $0.00 $0.00 $0.00 $0.00 $0.00 $12.13 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$12.13Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Negligible Change to Packaging"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 4 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 6000Manufacturing Assumption and Quote SummaryAPPENDIX G.1-60 (4of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)Part Number:6003-N0101-01-50Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Additional Electrical Connections due to Turbo &DI AddsNA1Install Connectors, SecureWiringOEM Engine Assembly Not Applicable General Assembly-OEM Engine Assembly, OEM52 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$1.60 $2.88 $4.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.48 $4.48Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1APower Train Control Module (PCM) Assembly -Hardware0602-N0101-011SAC$40.00$40.00$0.00 $40.002APower Train Control Module (PCM) Assembly -Software6002-N0101-501SAC$0.00$0.00$0.00 $0.003AEngine Electrical Systems (including WiringHarnesses, Earth Straps, Ignition Harness,Coils, Sockets)0603-N0101-01/301SAC$12.13$12.13$0.00 $12.134A$0.00$0.00$0.00 $0.005A$0.00$0.00$0.00 $0.006A$0.00$0.00$0.00 $0.007A$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$56.61T1 or OEM Total Manufacturing Cost:$52.13 $1.60 $2.88 $56.61 $0.00 $0.00 $0.00 $0.00 $0.00 $56.61T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(52.13)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.00 $1.60 $2.88 $4.48 $0.00 $0.00 $0.00 $0.00 $0.00 $4.48 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$4.48Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Negligible Change to Packaging"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 5 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 70Accessory SubsystemCase Study #0101MAQS WorksheetsFile:70 Accessory System 040209.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-70, 1 of 4Vacuum PumpManufacturing Assumption and Quote SummaryAPPENDIX G.1-70, (1of2)\Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Vacuum Pump AssemblyPart Number:7004-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Vacuum Pump Assembly 7004-N0101-011Final Assembly & TestVacuum PumpS Not Applicable General Assembly Mech. Assembly, MC240 30.000$0.00 $35.51 $125.19$0.00$0.44 $0.52 $0.970.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.97 $0.971B Base Vac Pump Rotor Support 7004-N0101-01-07-011Subassembly Exhaust and OilVent ValveS Not Applicable General Assembly Mech. Assembly, MC240 10.000$0.00 $35.51 $125.19$0.00$0.15 $0.52 $0.670.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.67 $0.67Purchase Part - High Impact Item (Full Cost Mapping)1A Base Vac Pump rotor support Casting 7004-N0101-01-07-01-021Machine Casting S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC257 10.000$0.00 $43.52 $100.05$0.00$0.17 $0.39 $0.560.30% 6.00% 4.00% 0.00%10.30% $0.06 $0.62 $0.621B Base Vac Pump rotor support Casting 7004-N0101-01-07-01-02-11Casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC183 0.50.542$1.10 $43.52 $100.05 $0.60 $0.12 $0.55 $1.260.30% 6.00% 4.00% 0.00%10.30% $0.13 $1.39 $1.392A Plate Oil vent relief 7004-N0101-01-07-01-041Stamping & Heat Treat S SPR-Steel, Coil Cut/Punch/Forming OperatorStamp/Form, SMS, LMC720 0.250.005$0.65 $42.18 $100.10 $0.00 $0.01 $0.14 $0.160.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.17 $0.173A Plate retainer/limiter - Oil vent relief 7004-N0101-01-07-01-051Stamping & Plating S LC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, SMS, LMC720 0.250.008$0.45 $42.18 $100.10 $0.00 $0.01 $0.14 $0.160.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.17 $0.174A Rotor Vac Pump 7004-N0101-01-081Induction Harden S Not Applicable Lathe/Turning Operator CNC Turning, MHC600 0.150.000$0.00 $37.60 $125.00$0.00$0.01 $0.21 $0.220.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.24 $0.244B Rotor Vac Pump 7004-N0101-01-081Machine for Critical Tol. S Not Applicable Lathe/Turning Operator CNC Turning, MHC109 0.850.000$0.00 $37.60 $125.00$0.00$0.29 $1.15 $1.440.30% 6.00% 4.00% 0.00%10.30% $0.15 $1.59 $1.594C Rotor Vac Pump raw part 7004-N0101-01-08-1-11PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, MHC240 0.50.631$2.00 $43.52 $150.14 $1.26 $0.09 $0.63 $1.980.30% 6.00% 4.00% 0.00%10.30% $0.20 $2.18 $2.185A Adapter Rotor Drive 7004-N0101-01-091PM Sinter S PM-SMF-FC0208 Mold/Cast/Sinter Operator Powder Metal, LMC360 0.50.139$1.00 $43.52 $100.14 $0.14 $0.06 $0.28 $0.480.30% 6.00% 4.00% 0.00%10.30% $0.05 $0.53 $0.536A Retainer Rotor drive adapter 7004-N0101-01-101Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/FormingOperatorStamp/Form, SMS, LMC1200 0.250.001$0.45 $42.18 $100.10 $0.00 $0.01 $0.08 $0.090.30% 6.00% 4.00% 0.00%10.30% $0.01 $0.10 $0.107A Vane Vacuum Pump 7004-N0101-01-051Form Edges and Plate S Not Applicable Cut/Punch/Forming OperatorStamp/Form, SMS, LMC720 0.250.000$0.00 $42.18 $100.10$0.00$0.01 $0.14 $0.150.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.17 $0.177B Vane Vacuum Pump 7004-N0101-01-05-011Stamp Out Form S LC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, SMS, LMC1200 0.250.167$0.45 $42.18 $100.10 $0.08 $0.01 $0.08 $0.170.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.18 $0.188A Seal Pump Vane to wall 7004-N0101-01-062PM Sinter S Not Applicable Mold/Cast/Sinter Operator Powder Metal, LMC600 0.250.000$0.00 $43.52 $100.14$0.00$0.02 $0.17 $0.190.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.20 $0.418B Seal Pump Vane to wall 7004-N0101-01-06-012PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, LMC480 0.250.026$2.00 $43.52 $100.14 $0.05 $0.02 $0.21 $0.280.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.31 $0.639A Cover Vacuum Pump 7004-N0101-01-011Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/FormingOperatorStamp/Form, SMS, LMC180 11.070$0.45 $42.18 $100.10 $0.48 $0.23 $0.56 $1.270.30% 6.00% 4.00% 0.00%10.30% $0.13 $1.40 $1.4010A Fitting Vac Outlet Port 7004-N0101-01-031Assemble Outlet Fitting S Purchased Parts General Assembly Mech. Assembly, LC450 10.265$1.00 $35.51 $100.19 $0.27 $0.08 $0.22 $0.570.30% 6.00% 4.00% 0.00%10.30% $0.06 $0.62 $0.6210B Fitting Vac Outlet Port 7004-N0101-01-03-011Injection Mold Housing S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS480 0.250.014$1.54 $43.52 $100.01 $0.02 $0.02 $0.21 $0.250.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.28 $0.28Purchase Part - Commodity ( Value taken from Purchase Part Database)PurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Fitting Clean Air Inlet 7004-N0101-01-07-01-031S$0.12$0.00 $0.122A Rivet solid, Oil vent plates 7004-N0101-01-07-01-061S$0.01$0.00 $0.013A Gasket Vac Pump Cover (SBR) 7004-N0101-01-021S$0.08$0.00 $0.084A Bolt - Vacuum Pump Housing 7080-N0101-104S$0.03$0.00 $0.125A Sleeve Anti Crush 7004-N0101-01-03-021B10A$0.01$0.01 $0.005B Check Valve 7004-N0101-01-03-031B10A$0.10$0.10 $0.005C Spring Check Valve 7004-N0101-01-03-041B10A$0.02$0.02 $0.005D Seat check valve spring 7004-N0101-01-03-051B10A$0.07$0.07 $0.005E O-Ring - Vac fitting 7004-N0101-01-041B10A$0.06$0.06 $0.006A Bolt - Vac Fitting 7080-N0101-101S$0.03$0.00 $0.03T1 or OEM Total Manufacturing Cost:$3.31 $1.81 $6.56 $11.69 $0.03 $0.58 $0.39 $0.00 $1.00 $12.68T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%T1 or OEM Mark-Up Values:----- ----- ----- -----$0.06 $0.82 $0.76 $0.32 $1.97Base Cost Impact to Vehicle:$3.31 $1.81 $6.56 $11.69 $0.09 $1.41 $1.15 $0.32 $2.96 $14.65 $0 $0Packaging Cost:$0.09Net Cost Impact to Vehicle:$14.74109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplieddirectly to T1 or OEM for Final or SubAssembly."Alpha-Numeric Character" = Indicatespurchase parts are brought in by T2/T3Supplier for Subassembly.3File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-70, 2 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Vacuum PumpManufacturing Assumption and Quote SummaryAPPENDIX G.1-70, (1of2)\Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Vacuum Pump AssemblyPart Number:7004-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.018 $35,4610.00%2,250,000 605.00%$200177432876596Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.08$1.00 9 $3.00 8 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.094Standard Pallet L4'xW4'xD3'Area = 122cm x 114 cm = 1440 sq. cmDepth = 86 cmPart Size 19x13x10Each Layer 9x6=54parts@ 8 layers = 432 PartsAssume Pallets Need to be ReplacedEvery 5 Years.File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-70, 3 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine AssemblyManufacturing Assumption and Quote SummaryAPPENDIX G.1-70, (2of2)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly of Accessory Subsystem Components to EnginePart Number:7000Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Vacuum Pump Assembly 7004-N0101-011Mount Vacuum Pump to HeadOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM113 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.74 $1.34 $2.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.08 $2.08Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemBolt - Vacuum Pump 7080-N0101-012S$0.00$0.03$0.00 $0.05Seal - Vacuum Pump to Head 7004-N0101-01-111S$0.00$0.08$0.00 $0.080$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$2.20T1 or OEM Total Manufacturing Cost:$0.13 $0.74 $1.34 $2.20 $0.00 $0.00 $0.00 $0.00 $0.00 $2.20T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.13 $0.74 $1.34 $2.20 $0.00 $0.00 $0.00 $0.00 $0.00 $2.20 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.20Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging for fasteners covered in piece price."S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includesFile:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-70, 4 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411

# 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 17-1 9 $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 46SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.03Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D03 Crank Drive Subsystem01 Crank ShaftA. Shaft - Crank03 01 -N0101- 01 1Diff.(10.61)$-$ -$(10.61)$(0.07)$ (0.74)$ (0.85)$-$(1.67)$-$(12.27)$03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)A Rod Subassembly - Connecting03 03 -N0101- 01 4Diff. 1.19$ -$ 1.11$2.30$0.01$ 0.15$ 0.14$ 0.06$0.36$-$2.66$A1 Bushing - Connecting Rod03 03 -N0101- 02 4PIA Rod SubassemblyA2 Rod - Connecting03 03 -N0101- 03 4PIA Rod SubassemblyB Cap- Connecting Rod03 03 -N0101- 04 4PIA Rod Subassembly04 Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins, Circlips)A Piston - Engine, Machined03 04 -N0101- 01 4Diff.(0.36)$0.39$ 3.04$3.07$0.34$ 0.22$ 0.20$ 0.08$0.85$-$3.92$B Ring/Clip - Piston Pin Retainer03 04 -N0101- 02 8Purchase Parts Engine Ass'yC Pin- Piston03 04 -N0101- 03 4Purchase Parts Engine Ass'yD Compression Ring - Piston, Top03 04 -N0101- 04 4Purchase Parts Engine Ass'yE Compression Ring - Piston, 2nd03 04 -N0101- 05 4Purchase Parts Engine Ass'yF Oil Ring SubassemblyF1 Spacer/Expander/Coil Spring - Oil Ring, Piston03 04 -N0101- 07 4Purchase Parts Engine Ass'yF2 Rail(s) - Oil Ring, Piston03 04 -N0101- 08 4Purchase Parts Engine Ass'y90 Bearing Elements: Connecting Rod Bearing Shells,Connecting Rod BushA Bearing - Connecting Rod to Crank Shaft03 90 -N0101- 01 8Purchase Parts Engine Ass'y100 Engine AssemblyA Assembly of Crank Drive Subsystem Components to Engine03 00 -N0101- 01 NADiff.5.69$ -$ -$5.69$-$ -$ -$ -$-$-$5.69$($4.09)0.39$ 4.15$0.46$0.28$(0.37)$ (0.51)$0.14$(0.46)$-$0.00$NOTES:1.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMName/Description Part Number

Item Subsystem Sub-Subsystem AssemblyManufacturingTotalManufacturingCost(Component/Assembly)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-03, 2 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.03Printed: 12/9/200903 Crank Drive Subsystem01 Crank ShaftA. Shaft - Crank03 01 -N0101- 01 1Diff.03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)A Rod Subassembly - Connecting03 03 -N0101- 01 4Diff.A1 Bushing - Connecting Rod03 03 -N0101- 02 4PIA Rod SubassemblyA2 Rod - Connecting03 03 -N0101- 03 4PIA Rod SubassemblyB Cap- Connecting Rod03 03 -N0101- 04 4PIA Rod Subassembly04 Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins, Circlips)A Piston - Engine, Machined03 04 -N0101- 01 4Diff.B Ring/Clip - Piston Pin Retainer03 04 -N0101- 02 8Purchase Parts Engine Ass'yC Pin- Piston03 04 -N0101- 03 4Purchase Parts Engine Ass'yD Compression Ring - Piston, Top03 04 -N0101- 04 4Purchase Parts Engine Ass'yE Compression Ring - Piston, 2nd03 04 -N0101- 05 4Purchase Parts Engine Ass'yF Oil Ring SubassemblyF1 Spacer/Expander/Coil Spring - Oil Ring, Piston03 04 -N0101- 07 4Purchase Parts Engine Ass'yF2 Rail(s) - Oil Ring, Piston03 04 -N0101- 08 4Purchase Parts Engine Ass'y90 Bearing Elements: Connecting Rod Bearing Shells,Connecting Rod BushA Bearing - Connecting Rod to Crank Shaft03 90 -N0101- 01 8Purchase Parts Engine Ass'y100 Engine AssemblyA Assembly of Crank Drive Subsystem Components to Engine03 00 -N0101- 01 NADiff.NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Name/Description Part Number

Item Subsystem Sub-Subsystem AssemblyGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)ManufacturingFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-03, 3 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.03Printed: 12/9/200903 Crank Drive Subsystem01 Crank ShaftA. Shaft - Crank03 01 -N0101- 01 1Diff.03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)A Rod Subassembly - Connecting03 03 -N0101- 01 4Diff.A1 Bushing - Connecting Rod03 03 -N0101- 02 4PIA Rod SubassemblyA2 Rod - Connecting03 03 -N0101- 03 4PIA Rod SubassemblyB Cap- Connecting Rod03 03 -N0101- 04 4PIA Rod Subassembly04 Pistons (Assemblies, Including Pistons, Ring Packs, Piston Pins, Circlips)A Piston - Engine, Machined03 04 -N0101- 01 4Diff.B Ring/Clip - Piston Pin Retainer03 04 -N0101- 02 8Purchase Parts Engine Ass'yC Pin- Piston03 04 -N0101- 03 4Purchase Parts Engine Ass'yD Compression Ring - Piston, Top03 04 -N0101- 04 4Purchase Parts Engine Ass'yE Compression Ring - Piston, 2nd03 04 -N0101- 05 4Purchase Parts Engine Ass'yF Oil Ring SubassemblyF1 Spacer/Expander/Coil Spring - Oil Ring, Piston03 04 -N0101- 07 4Purchase Parts Engine Ass'yF2 Rail(s) - Oil Ring, Piston03 04 -N0101- 08 4Purchase Parts Engine Ass'y90 Bearing Elements: Connecting Rod Bearing Shells,Connecting Rod BushA Bearing - Connecting Rod to Crank Shaft03 90 -N0101- 01 8Purchase Parts Engine Ass'y100 Engine AssemblyA Assembly of Crank Drive Subsystem Components to Engine03 00 -N0101- 01 NADiff.NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Name/Description Part Number

Item Subsystem Sub-Subsystem AssemblyGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$0.00 -$ -$-$-$ -$ -$ -$-$-$-$($10.61)-$ -$(10.61)$(0.07)$ (0.74)$ (0.85)$-$(1.67)$-$(12.27)$$1.19 -$ 1.11$2.30$0.01$ 0.15$ 0.14$ 0.06$0.36$-$2.66$($0.36)0.39$ 3.04$3.07$0.34$ 0.22$ 0.20$ 0.08$0.85$-$3.92$$5.69 -$ -$5.69$-$ -$ -$ -$-$-$5.69$(4.09)$0.39$ 4.15$0.46$0.28$(0.37)$ (0.51)$0.14$(0.46)$-$0.00$TotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)ManufacturingNetComponent/AssemblyCost Impact toOEMTotalPackagingCost(Component/Assembly)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-03, 4 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATELight-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.04Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D04 Counter Balance Subsystem01 Moved PartsA Balance Shaft Subassembly ( Part of Oil Pump Assembly)04 01 B0101 01 1Full -$ -$ -$-$-$ -$ -$ -$-$-$-$100A Assembly of Balance Shaft Assembly to Engine04 00 B0101 01 NAFull -$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.ManufacturingTotalManufacturingCost(Component/Assembly)

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-04, 5 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATELight-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.04Printed: 12/9/200904 Counter Balance Subsystem01 Moved PartsA Balance Shaft Subassembly ( Part of Oil Pump Assembly)04 01 B0101 01 1Full100A Assembly of Balance Shaft Assembly to Engine04 00 B0101 01 NAFullNOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D8.53$ 5.83$ 10.65$25.01$0.82$ 3.22$ 2.98$ 0.92$7.95$0.05$33.01$1.83$ 0.39$ 0.71$2.93$-$ -$ -$ -$-$-$2.93$10.37$ 6.22$ 11.36$27.94$0.82$ 3.22$ 2.98$ 0.92$7.95$0.05$35.95$BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-04, 6 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATELight-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.04Printed: 12/9/200904 Counter Balance Subsystem01 Moved PartsA Balance Shaft Subassembly ( Part of Oil Pump Assembly)04 01 B0101 01 1Full100A Assembly of Balance Shaft Assembly to Engine04 00 B0101 01 NAFullNOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D($8.53) (5.83)$ (10.65)$(25.01)$(0.82)$ (3.22)$ (2.98)$ (0.92)$(7.95)$(0.05)$(33.01)$($1.83) (0.39)$ (0.71)$(2.93)$-$ -$ -$ -$-$-$(2.93)$(10.37)$ (6.22)$ (11.36)$(27.94)$(0.82)$ (3.22)$ (2.98)$ (0.92)$(7.95)$(0.05)$(35.95)$MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)ManufacturingTotalManufacturingCost(Component/Assembly)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-04, 7 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.05Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D05 Cylinder Block Subsystem01 Cylinder BlockA Cylinder Block Assembly - Machined w. Studs, Plugs, etc.05 01 -N0101- 01 1Diff.(7.96)$0.07$ 0.99$(6.90)$(0.41)$ (0.56)$ (0.62)$-$(1.59)$-$(8.49)$A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc05 01 -N0101- 02 1 PIAA1.1 Cylinder Block Subassembly - Cast05 01 -N0101- 03 1 PIAA1.1.1Cylinder Liners - Cast Iron05 01 -N0101- 04 1 PIA03 BedplatesDiff.(4.36)$-$ -$(4.36)$(0.25)$ (0.34)$ (0.38)$-$(0.98)$-$(5.34)$A Bed Plate Assembly - Machined w. Studs, Plugs, etc.05 03 -N0101- 01 1A1 Bed Plate Assembly - Machined w/o. Studs, Plugs,etc.05 03 -N0101- 02 1 PIAA1.1 Bed Plate Subassembly - Cast05 03 -N0101- 02 1 PIAA1.1.1Bearing Cap - Bolt Through - Insert, Steel05 03 -N0101- 03 5 PIA04 Piston CoolingA Squirter - Oil, Piston Cooler05 04 -N0101- 01 4Full 2.60$ 0.64$ 3.62$6.86$0.04$ 0.87$ 0.58$ -$1.49$0.04$8.38$B Bolt - Piston Cooler Valve/Retainer05 04 -N0101- 02 4 (Grouped w. A)90 Bearing Elements: Crankshaft bearing shells(Costs shown per enginebearing set)ABearing - Crankshaft, Block 1/2 Bearing (Top w. Lub. Pass.)05 90 -N0101- 01 1 5pcs/set Diff. 2.13$ -$ -$2.13$-$ -$ -$ -$-$-$2.13$B Bearing/Shim - Crankshaft Thrust05 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 AssemblyA Assembly of Additional Cylinder Block ComponentsDiff. -$ 0.65$ 1.17$1.82$0.09$ 0.86$ 0.99$ -$1.94$-$3.75$(7.59)$1.36$ 5.78$(0.46)$(0.53)$0.83$ 0.56$ -$0.86$0.04$0.44$NOTES:1.MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMManufacturingTotalManufacturingCost(Component/Assembly)

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile: SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-05, 8 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.05Printed: 12/9/200905 Cylinder Block Subsystem01 Cylinder BlockA Cylinder Block Assembly - Machined w. Studs, Plugs, etc.05 01 -N0101- 01 1Diff.A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc05 01 -N0101- 02 1 PIAA1.1 Cylinder Block Subassembly - Cast05 01 -N0101- 03 1 PIAA1.1.1Cylinder Liners - Cast Iron05 01 -N0101- 04 1 PIA03 BedplatesDiff.A Bed Plate Assembly - Machined w. Studs, Plugs, etc.05 03 -N0101- 01 1A1 Bed Plate Assembly - Machined w/o. Studs, Plugs,etc.05 03 -N0101- 02 1 PIAA1.1 Bed Plate Subassembly - Cast05 03 -N0101- 02 1 PIAA1.1.1Bearing Cap - Bolt Through - Insert, Steel05 03 -N0101- 03 5 PIA04 Piston CoolingA Squirter - Oil, Piston Cooler05 04 -N0101- 01 4FullB Bolt - Piston Cooler Valve/Retainer05 04 -N0101- 02 4 (Grouped w. A)90 Bearing Elements: Crankshaft bearing shells(Costs shown per enginebearing set)ABearing - Crankshaft, Block 1/2 Bearing (Top w. Lub. Pass.)05 90 -N0101- 01 1 5pcs/set Diff.B Bearing/Shim - Crankshaft Thrust05 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 AssemblyA Assembly of Additional Cylinder Block ComponentsDiff.NOTES:1. Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)ManufacturingBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File: SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-05, 9 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.05Printed: 12/9/200905 Cylinder Block Subsystem01 Cylinder BlockA Cylinder Block Assembly - Machined w. Studs, Plugs, etc.05 01 -N0101- 01 1Diff.A1 Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc05 01 -N0101- 02 1 PIAA1.1 Cylinder Block Subassembly - Cast05 01 -N0101- 03 1 PIAA1.1.1Cylinder Liners - Cast Iron05 01 -N0101- 04 1 PIA03 BedplatesDiff.A Bed Plate Assembly - Machined w. Studs, Plugs, etc.05 03 -N0101- 01 1A1 Bed Plate Assembly - Machined w/o. Studs, Plugs,etc.05 03 -N0101- 02 1 PIAA1.1 Bed Plate Subassembly - Cast05 03 -N0101- 02 1 PIAA1.1.1Bearing Cap - Bolt Through - Insert, Steel05 03 -N0101- 03 5 PIA04 Piston CoolingA Squirter - Oil, Piston Cooler05 04 -N0101- 01 4FullB Bolt - Piston Cooler Valve/Retainer05 04 -N0101- 02 4 (Grouped w. A)90 Bearing Elements: Crankshaft bearing shells(Costs shown per enginebearing set)ABearing - Crankshaft, Block 1/2 Bearing (Top w. Lub. Pass.)05 90 -N0101- 01 1 5pcs/set Diff.B Bearing/Shim - Crankshaft Thrust05 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 AssemblyA Assembly of Additional Cylinder Block ComponentsDiff.NOTES:1. Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D($7.96)0.07$ 0.99$(6.90)$(0.41)$ (0.56)$ (0.62)$-$(1.59)$-$(8.49)$($4.36)-$ -$(4.36)$(0.25)$ (0.34)$ (0.38)$-$(0.98)$-$(5.34)$$0.00 -$ -$-$-$ -$ -$ -$-$-$-$$2.60 0.64$ 3.62$6.86$0.04$ 0.87$ 0.58$ -$1.49$0.04$8.38$`$2.13 -$ -$2.13$-$ -$ -$ -$-$-$2.13$$0.00 0.65$ 1.17$1.82$0.09$ 0.86$ 0.99$ -$1.94$-$3.75$(7.59)$1.36$ 5.78$(0.46)$(0.53)$0.83$ 0.56$ -$0.86$0.04$0.44$TotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)ManufacturingMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile: SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-05, 10 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATELight-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.06Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D06 Cylinder Head Subsystem01 Cylinder HeadA Cylinder Head Assembly - Machined w. Studs, Valves, etc.06 01 -N0101- 01 1Diff(0.83)$0.63$ 6.11$5.91$1.79$ 0.54$ 0.61$ -$2.94$-$8.85$A1 Cylinder Head - Machined w/o. Studs, Valves, etc.06 01 -N0101- 02 1 PIA Head AssemblyA1.1 Cylinder Head Subassembly - Cast06 01 -N0101- 03 1 PIA Head Assembly02 Valve Guides. Valve SeatsC Seat - Intake Valve06 02 -N0101- 03 8Diff0.34$ -$ -$0.34$-$ -$ -$ -$-$-$0.34$D Seat - Exhaust Valve06 02 -N0101- 04 8 (Grouped w. C)06 Camshaft Bearing HousingCCap, Head (Fuel Pump & Vacuum Mount)06 06 -N0101- 03 1Full0.67$ 0.18$ 0.83$1.69$0.01$ 0.11$ 0.10$ 0.04$0.26$0.03$1.98$80 Boltings: Cylinder Head, Cylinder Head Cover, ManifoldBoltings & Screws GeneralA Bolt - Cap Bearing, Camshaft06 80 -N0101- 01 4 PIA Engine AssemblyDowel Pins/Plugs/Studs - Cylinder HeadA Bolt - Manifold, Exhaust06 80 -N0101- 10 10 PIA Engine Assembly85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....A Gasket - Cylinder Head to Block 06 85 -N0101- 01 1Diff.1.46$ -$ -$1.46$-$ -$ -$ -$-$-$1.46$100 Engine AssemblyA Assembly of Additional/Revised Cylinder Head Components1Diff.3.92$ -$ -$3.92$-$ -$ -$ -$-$-$3.92$5.57$ 0.81$ 6.94$13.32$1.80$ 0.65$ 0.71$ 0.04$3.20$0.03$16.55$NOTES:1.MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEM

Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem AssemblyNEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.ManufacturingTotalManufacturingCost(Component/Assembly)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-06, 11 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATELight-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.06Printed: 12/9/200906 Cylinder Head Subsystem01 Cylinder HeadA Cylinder Head Assembly - Machined w. Studs, Valves, etc.06 01 -N0101- 01 1DiffA1 Cylinder Head - Machined w/o. Studs, Valves, etc.06 01 -N0101- 02 1 PIA Head AssemblyA1.1 Cylinder Head Subassembly - Cast06 01 -N0101- 03 1 PIA Head Assembly02 Valve Guides. Valve SeatsC Seat - Intake Valve06 02 -N0101- 03 8DiffD Seat - Exhaust Valve06 02 -N0101- 04 8 (Grouped w. C)06 Camshaft Bearing HousingCCap, Head (Fuel Pump & Vacuum Mount)06 06 -N0101- 03 1Full80 Boltings: Cylinder Head, Cylinder Head Cover, ManifoldBoltings & Screws GeneralA Bolt - Cap Bearing, Camshaft06 80 -N0101- 01 4 PIA Engine AssemblyDowel Pins/Plugs/Studs - Cylinder HeadA Bolt - Manifold, Exhaust06 80 -N0101- 10 10 PIA Engine Assembly85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....A Gasket - Cylinder Head to Block 06 85 -N0101- 01 1Diff.100 Engine AssemblyA Assembly of Additional/Revised Cylinder Head Components1Diff.NOTES:1. Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)ManufacturingBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-06, 12 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATELight-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.06Printed: 12/9/200906 Cylinder Head Subsystem01 Cylinder HeadA Cylinder Head Assembly - Machined w. Studs, Valves, etc.06 01 -N0101- 01 1DiffA1 Cylinder Head - Machined w/o. Studs, Valves, etc.06 01 -N0101- 02 1 PIA Head AssemblyA1.1 Cylinder Head Subassembly - Cast06 01 -N0101- 03 1 PIA Head Assembly02 Valve Guides. Valve SeatsC Seat - Intake Valve06 02 -N0101- 03 8DiffD Seat - Exhaust Valve06 02 -N0101- 04 8 (Grouped w. C)06 Camshaft Bearing HousingCCap, Head (Fuel Pump & Vacuum Mount)06 06 -N0101- 03 1Full80 Boltings: Cylinder Head, Cylinder Head Cover, ManifoldBoltings & Screws GeneralA Bolt - Cap Bearing, Camshaft06 80 -N0101- 01 4 PIA Engine AssemblyDowel Pins/Plugs/Studs - Cylinder HeadA Bolt - Manifold, Exhaust06 80 -N0101- 10 10 PIA Engine Assembly85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....A Gasket - Cylinder Head to Block 06 85 -N0101- 01 1Diff.100 Engine AssemblyA Assembly of Additional/Revised Cylinder Head Components1Diff.NOTES:1. Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D($0.83)0.63$ 6.11$5.91$1.79$ 0.54$ 0.61$ -$2.94$-$8.85$$0.34 -$ -$0.34$-$ -$ -$ -$-$-$0.34$$0.67 0.18$ 0.83$1.69$0.01$ 0.11$ 0.10$ 0.04$0.26$0.03$1.98$$1.46 -$ -$1.46$-$ -$ -$ -$-$-$1.46$$3.92 -$ -$3.92$-$ -$ -$ -$-$-$3.92$5.57$ 0.81$ 6.94$13.32$1.80$ 0.65$ 0.71$ 0.04$3.20$0.03$16.55$TotalManufacturingCost(Component/Assembly)ManufacturingINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-06, 13 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.07Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D07 Valve Train Subsystem01 Inlet ValvesA Valve - Intake07 01 -N0101- 01 8Diff. 8.66$ -$ -$8.66$0.06$ 0.61$ 0.69$ 0.35$1.71$-$10.37$02 Outlet ValvesA Valve - Exhaust07 02 -N0101- 01 8Exhaust Valves grouped with IntakeValve CostsDiff.06 CamshaftsA Camshaft Assembly - Intake Machined07 06 -N0101- 01 1Diff.(0.26)$-$ -$(0.26)$(0.01)$ (0.02)$ (0.02)$ (0.01)$(0.05)$-$(0.31)$A1 Camshaft - Intake Machined07 06 -N0101- 02 1 PIAB Camshaft Assembly - Exhaust Machined07 06 -N0101- 10 1Exhaust Cam Shaft grouped withIntake Cam Shaft CostsDiff.B1 Camshaft - Exhaust Machine07 06 -N0101- 11 1 PIA100 Engine AssemblyA Engine Assembly ImpactMark-up affect only Diff. -$ -$ -$-$-$ -$ -$ -$-$-$-$$8.40 -$ -$8.40$0.05$ 0.59$ 0.68$ 0.34$1.65$-$10.06$NOTES:1.MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEM

Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem AssemblyNEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.ManufacturingTotalManufacturingCost(Component/Assembly)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-07, 14 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.07Printed: 12/9/200907 Valve Train Subsystem01 Inlet ValvesA Valve - Intake07 01 -N0101- 01 8Diff.02 Outlet ValvesA Valve - Exhaust07 02 -N0101- 01 8Exhaust Valves grouped with IntakeValve CostsDiff.06 CamshaftsA Camshaft Assembly - Intake Machined07 06 -N0101- 01 1Diff.A1 Camshaft - Intake Machined07 06 -N0101- 02 1 PIAB Camshaft Assembly - Exhaust Machined07 06 -N0101- 10 1Exhaust Cam Shaft grouped withIntake Cam Shaft CostsDiff.B1 Camshaft - Exhaust Machine07 06 -N0101- 11 1 PIA100 Engine AssemblyA Engine Assembly ImpactMark-up affect only Diff.NOTES:1. Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)ManufacturingBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-07, 15 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.07Printed: 12/9/200907 Valve Train Subsystem01 Inlet ValvesA Valve - Intake07 01 -N0101- 01 8Diff.02 Outlet ValvesA Valve - Exhaust07 02 -N0101- 01 8Exhaust Valves grouped with IntakeValve CostsDiff.06 CamshaftsA Camshaft Assembly - Intake Machined07 06 -N0101- 01 1Diff.A1 Camshaft - Intake Machined07 06 -N0101- 02 1 PIAB Camshaft Assembly - Exhaust Machined07 06 -N0101- 10 1Exhaust Cam Shaft grouped withIntake Cam Shaft CostsDiff.B1 Camshaft - Exhaust Machine07 06 -N0101- 11 1 PIA100 Engine AssemblyA Engine Assembly ImpactMark-up affect only Diff.NOTES:1. Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$8.66 -$ -$8.66$0.06$ 0.61$ 0.69$ 0.35$1.71$-$10.37$($0.26)-$ -$(0.26)$(0.01)$ (0.02)$ (0.02)$ (0.01)$(0.05)$-$(0.31)$$0.00 -$ -$-$-$ -$ -$ -$-$-$-$8.40$ -$ -$8.40$0.05$ 0.59$ 0.68$ 0.34$1.65$-$10.06$TotalManufacturingCost(Component/Assembly)ManufacturingINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-07, 16 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.08Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D08 Timing Drive Subsystem01 Timing Wheels (Sprockets)A Sprocket - Crankshaft, Timing Drive08 01 -N0101- 01 1 Smart Sprocket Mod 1.60$ -$ -$1.60$-$ -$ -$ -$-$-$1.60$100 Engine AssemblyA Timing Drive Impact to engine assemblyNA-$ -$ -$-$-$ -$ -$ -$-$-$-$$1.60 -$ -$1.60$-$ -$ -$ -$-$-$1.60$NOTES:1.ManufacturingTotalManufacturingCost(Component/Assembly)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem AssemblyMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEM= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-08, 17 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.08Printed: 12/9/200908 Timing Drive Subsystem01 Timing Wheels (Sprockets)A Sprocket - Crankshaft, Timing Drive08 01 -N0101- 01 1 Smart Sprocket Mod100 Engine AssemblyA Timing Drive Impact to engine assemblyNANOTES:1.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-08, 18 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.08Printed: 12/9/200908 Timing Drive Subsystem01 Timing Wheels (Sprockets)A Sprocket - Crankshaft, Timing Drive08 01 -N0101- 01 1 Smart Sprocket Mod100 Engine AssemblyA Timing Drive Impact to engine assemblyNANOTES:1.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$1.60 -$ -$1.60$-$ -$ -$ -$-$-$1.60$$0.00 -$ -$-$-$ -$ -$ -$-$-$-$1.60$ -$ -$1.60$-$ -$ -$ -$-$-$1.60$TotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)ManufacturingMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-08, 19 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.10Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D10 Intake Subsystem01 Intake ManifoldsA Manifold Assembly - Intake10 01 -N0101- 01 1Diff.(10.66)$ (0.01)$ (0.10)$(10.78)$(0.05)$ (0.70)$ (0.65)$ (0.27)$(1.67)$(0.28)$(12.73)$100 Engine AssemblyA Timing Drive Impact to engine assembly10 00 N01010011 NA-$ -$ -$-$-$ -$ -$ -$-$-$-$($10.66) (0.01)$ (0.10)$(10.78)$(0.05)$ (0.70)$ (0.65)$ (0.27)$(1.67)$(0.28)$(12.73)$NOTES:1.ManufacturingTotalManufacturingCost(Component/Assembly)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem AssemblyMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMNEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-10, 20 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.10Printed: 12/9/200910 Intake Subsystem01 Intake ManifoldsA Manifold Assembly - Intake10 01 -N0101- 01 1Diff.100 Engine AssemblyA Timing Drive Impact to engine assembly10 00 N01010011 NANOTES:1.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-10, 21 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.10Printed: 12/9/200910 Intake Subsystem01 Intake ManifoldsA Manifold Assembly - Intake10 01 -N0101- 01 1Diff.100 Engine AssemblyA Timing Drive Impact to engine assembly10 00 N01010011 NANOTES:1.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D($10.66) (0.01)$ (0.10)$(10.78)$(0.05)$ (0.70)$ (0.65)$ (0.27)$(1.67)$(0.28)$(12.73)$$0.00 -$ -$-$-$ -$ -$ -$-$-$-$(10.66)$ (0.01)$ (0.10)$(10.78)$(0.05)$ (0.70)$ (0.65)$ (0.27)$(1.67)$(0.28)$(12.73)$TotalManufacturingCost(Component/Assembly)ManufacturingINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-10, 22 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.11Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D11 Fuel Induction Subsystem01 Fuel RailsA Fuel Rail w. High Pressure Sensor Assembly11 01 -N0101- 01 1Full 11.09$ 1.81$ 5.70$18.59$0.06$ 1.12$ 0.74$ 0.19$2.10$0.07$20.76$A1 Fuel Rail - High Pressure11 01 -N0101- 02 1PIA Fuel Rail AssemblyA2 Sensor - Fuel, High Pressure11 01 -N0101- 03 1PIA Fuel Rail Assembly04 Fuel InjectorsA Fuel Injector Assembly - Solenoid, 7 Hole11 04 -N0101- 01 4Full $8.63 $5.88 $25.7440.25$0.43$ 4.72$ 5.03$ 2.01$12.18$0.05$52.49$07 Fuel Injection PumpsA11 07 -N0101- 01 1Full $16.99 $8.24 $28.3253.55$0.73$ 6.36$ 6.40$ 2.46$15.96$0.11$69.61$70 Pipes, Hoses: Low Pressure, High PressureA Pipe Assembly - Fuel, High Pressure, Pump to Rail11 70 -N0101- 01 1Full $0.39 $0.34 $1.061.80$0.01$ 0.11$ 0.07$ 0.02$0.20$0.01$2.01$80 BoltingA Bolt - Fuel Rail11 80 -N0101- 01 4PIA Engine Assembly Diff.B Bolt - Fuel Pump11 80 -N0101- 02 3PIA Engine Assembly FullC Retainer - Fuel Injector11 80 -N0101- 03 4PIA Injector FullD Washer, Retainer - Fuel Injector11 80 -N0101- 04 4PIA Injector FullE O-ring Retainer, Fuel Injector11 80 -N0101- 05 4PIA Injector FullF Spacer - Retainer, Fuel Injector11 80 -N0101- 06 4PIA Injector Full85 Sealing ElementsA Seal - High Pressure Fuel Pump to Cylinder Head11 85 -N0101- 01 1PIA Fuel Pump Full100 Engine AssemblyA Fuel Induction impact to engine assemblyDiff. 0.15$ 1.13$ 2.04$3.33$-$ -$ -$ -$-$-$3.33$$37.24 17.41$ 62.87$117.52$1.23$ 12.30$ 12.25$ 4.67$30.44$0.24$148.20$NOTES:1.MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMManufacturingTotalManufacturingCost(Component/Assembly)

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off IntakeCam)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-11, 23 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.11Printed: 12/9/200911 Fuel Induction Subsystem01 Fuel RailsA Fuel Rail w. High Pressure Sensor Assembly11 01 -N0101- 01 1FullA1 Fuel Rail - High Pressure11 01 -N0101- 02 1PIA Fuel Rail AssemblyA2 Sensor - Fuel, High Pressure11 01 -N0101- 03 1PIA Fuel Rail Assembly04 Fuel InjectorsA Fuel Injector Assembly - Solenoid, 7 Hole11 04 -N0101- 01 4Full07 Fuel Injection PumpsA11 07 -N0101- 01 1Full70 Pipes, Hoses: Low Pressure, High PressureA Pipe Assembly - Fuel, High Pressure, Pump to Rail11 70 -N0101- 01 1Full80 BoltingA Bolt - Fuel Rail11 80 -N0101- 01 4PIA Engine Assembly Diff.B Bolt - Fuel Pump11 80 -N0101- 02 3PIA Engine Assembly FullC Retainer - Fuel Injector11 80 -N0101- 03 4PIA Injector FullD Washer, Retainer - Fuel Injector11 80 -N0101- 04 4PIA Injector FullE O-ring Retainer, Fuel Injector11 80 -N0101- 05 4PIA Injector FullF Spacer - Retainer, Fuel Injector11 80 -N0101- 06 4PIA Injector Full85 Sealing ElementsA Seal - High Pressure Fuel Pump to Cylinder Head11 85 -N0101- 01 1PIA Fuel Pump Full100 Engine AssemblyA Fuel Induction impact to engine assemblyDiff.NOTES:1. Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off IntakeCam)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D1.36$ 1.46$ 2.35$5.18$0.02$ 0.31$ 0.21$ 0.05$0.58$0.07$5.83$4.13$ 4.15$ 19.46$27.74$0.26$ 2.79$ 2.98$ 1.26$7.28$0.05$35.07$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$5.49$ 5.61$ 21.81$32.91$0.27$ 3.10$ 3.19$ 1.31$7.87$0.12$40.90$NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)ManufacturingBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-11, 24 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.11Printed: 12/9/200911 Fuel Induction Subsystem01 Fuel RailsA Fuel Rail w. High Pressure Sensor Assembly11 01 -N0101- 01 1FullA1 Fuel Rail - High Pressure11 01 -N0101- 02 1PIA Fuel Rail AssemblyA2 Sensor - Fuel, High Pressure11 01 -N0101- 03 1PIA Fuel Rail Assembly04 Fuel InjectorsA Fuel Injector Assembly - Solenoid, 7 Hole11 04 -N0101- 01 4Full07 Fuel Injection PumpsA11 07 -N0101- 01 1Full70 Pipes, Hoses: Low Pressure, High PressureA Pipe Assembly - Fuel, High Pressure, Pump to Rail11 70 -N0101- 01 1Full80 BoltingA Bolt - Fuel Rail11 80 -N0101- 01 4PIA Engine Assembly Diff.B Bolt - Fuel Pump11 80 -N0101- 02 3PIA Engine Assembly FullC Retainer - Fuel Injector11 80 -N0101- 03 4PIA Injector FullD Washer, Retainer - Fuel Injector11 80 -N0101- 04 4PIA Injector FullE O-ring Retainer, Fuel Injector11 80 -N0101- 05 4PIA Injector FullF Spacer - Retainer, Fuel Injector11 80 -N0101- 06 4PIA Injector Full85 Sealing ElementsA Seal - High Pressure Fuel Pump to Cylinder Head11 85 -N0101- 01 1PIA Fuel Pump Full100 Engine AssemblyA Fuel Induction impact to engine assemblyDiff.NOTES:1. Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Fuel Pump - High Pressure w. Vol.Cotrol Valve (Driven-Off IntakeCam)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$9.72 0.35$ 3.35$13.42$0.04$ 0.81$ 0.54$ 0.13$1.52$(0.00)$14.93$$4.50 1.74$ 6.28$12.51$0.18$ 1.93$ 2.05$ 0.75$4.90$0.01$17.42$$16.99 8.24$ 28.32$53.55$0.73$ 6.36$ 6.40$ 2.46$15.96$0.11$69.61$$0.39 0.34$ 1.06$1.80$0.01$ 0.11$ 0.07$ 0.02$0.20$0.01$2.01$$0.15 1.13$ 2.04$3.33$-$ -$ -$ -$-$-$3.33$31.75$ 11.80$ 41.05$84.60$0.95$ 9.20$ 9.06$ 3.36$22.57$0.12$107.30$TotalManufacturingCost(Component/Assembly)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMManufacturingFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-11, 25 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.12Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D12 Exhaust Subsystem01 Exhaust ManifoldA Manifold - Exhaust, Dual Wall12 01 -N0101- 01 1Diff. 22.64$ 0.03$ 3.03$25.70$2.97$ 1.85$ 1.71$ 0.71$7.25$(0.12)$32.82$75 BracketsB Bracket Subassembly- Heat Shield, Top, Turbo12 75 -N0101- 02 1Diff.1.77$ 0.08$ 0.07$1.91$0.01$ 0.11$ 0.08$ -$0.20$-$2.11$80 BoltingA Nut- Manifold Exhaust to Cylinder Head12 80 -N0101- 01 10 PIA Engine AssemblyF Nut - Turbo to C.C. Catalytic Converter12 80 -N0101- 06 3 PIA Engine AssemblyG Nut - Exhaust Manifold to Turbo12 80 -N0101- 07 4 Covered in Air Induction85 Sealing ElementsA Gasket Assembly - Exhaust Manifold12 85 -B0101- 01 1Diff.0.95$ -$ -$0.95$-$ -$ -$ -$-$-$0.95$Bracket Subassembly - Exhaust Manifold w. Integrated Gasket12 75 -N0101- 01 1Gasket integrated into heatshield mounting bracket.100 Vehicle Operations or Engine AssemblyA Assembly of Exhaust System Components to Engine12 00 -N0101- 01 Component Cost OnlyDiff.1.89$ -$ -$1.89$-$ -$ -$ -$-$-$1.89$$27.24 0.11$ 3.09$30.45$2.97$ 1.97$ 1.79$ 0.71$7.44$(0.12)$37.77$NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.ManufacturingTotalManufacturingCost(Component/Assembly)NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-12, 26 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.12Printed: 12/9/200912 Exhaust Subsystem01 Exhaust ManifoldA Manifold - Exhaust, Dual Wall12 01 -N0101- 01 1Diff.75 BracketsB Bracket Subassembly- Heat Shield, Top, Turbo12 75 -N0101- 02 1Diff.80 BoltingA Nut- Manifold Exhaust to Cylinder Head12 80 -N0101- 01 10 PIA Engine AssemblyF Nut - Turbo to C.C. Catalytic Converter12 80 -N0101- 06 3 PIA Engine AssemblyG Nut - Exhaust Manifold to Turbo12 80 -N0101- 07 4 Covered in Air Induction85 Sealing ElementsA Gasket Assembly - Exhaust Manifold12 85 -B0101- 01 1Diff.Bracket Subassembly - Exhaust Manifold w. Integrated Gasket12 75 -N0101- 01 1Gasket integrated into heatshield mounting bracket.100 Vehicle Operations or Engine AssemblyA Assembly of Exhaust System Components to Engine12 00 -N0101- 01 Component Cost OnlyDiff.NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-12, 27 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.12Printed: 12/9/200912 Exhaust Subsystem01 Exhaust ManifoldA Manifold - Exhaust, Dual Wall12 01 -N0101- 01 1Diff.75 BracketsB Bracket Subassembly- Heat Shield, Top, Turbo12 75 -N0101- 02 1Diff.80 BoltingA Nut- Manifold Exhaust to Cylinder Head12 80 -N0101- 01 10 PIA Engine AssemblyF Nut - Turbo to C.C. Catalytic Converter12 80 -N0101- 06 3 PIA Engine AssemblyG Nut - Exhaust Manifold to Turbo12 80 -N0101- 07 4 Covered in Air Induction85 Sealing ElementsA Gasket Assembly - Exhaust Manifold12 85 -B0101- 01 1Diff.Bracket Subassembly - Exhaust Manifold w. Integrated Gasket12 75 -N0101- 01 1Gasket integrated into heatshield mounting bracket.100 Vehicle Operations or Engine AssemblyA Assembly of Exhaust System Components to Engine12 00 -N0101- 01 Component Cost OnlyDiff.NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$22.64 0.03$ 3.03$25.70$2.97$ 1.85$ 1.71$ 0.71$7.25$(0.12)$32.82$$1.77 0.08$ 0.07$1.91$0.01$ 0.11$ 0.08$ -$0.20$-$2.11$$0.95 -$ -$0.95$-$ -$ -$ -$-$-$0.95$$1.89 -$ -$1.89$-$ -$ -$ -$-$-$1.89$27.24$ 0.11$ 3.09$30.45$2.97$ 1.97$ 1.79$ 0.71$7.44$(0.12)$37.77$MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)TotalManufacturingCost(Component/Assembly)ManufacturingFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-12, 28 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.13Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D13 Lubrication Subsystem (e.g.Oil Pans, Sumps)02 Oil PumpsA Oil Pump Assembly13 02 -N0101- 01 1 1 Diff. 3.08$ -$ -$3.08$0.02$ 0.22$ 0.25$ 0.12$0.61$-$3.69$06 Oil FilterA Filter Cooler Assembly - Oil (Includes Seals)13 06 -N0101- 01 11Diff. $2.93 $2.23 $5.3110.48$0.10$ 1.44$ 1.21$ 0.38$3.13$0.16$13.78$70 Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure, Low Pressure.A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet toTurbocharger 13 70 -N0101- 01 1(Shipped PIA to Filter/CoolerAssembly, although showingcost broke out separately)1Full $1.27 $0.80 $1.593.66$0.01$ 0.23$ 0.16$ -$0.40$0.03$4.09$B Tube Assembly - Oil, Turbo to Engine Block (PistonSquirter's)13 70 -N0101- 02 11Full$0.42 $0.81 $2.203.43$0.01$ 0.24$ 0.16$ -$0.41$0.06$3.90$80 Boltings & ClampsC Bolt - Filter Cooler Assembly13 80 -N0101- 03 4 PIA to Engine AssemblyD Bolt - Tube Assembly , Oil, Turbo Inlet13 80 -N0101- 09 1 PIA to Engine AssemblyE Clamp - Tube Assembly, Oil, Cooler/Filter Outlet13 80 -N0101- 05 1 PIA Tube Assembly-Oil, ...F Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet13 80 -N0101- 06 2 PIA to Engine Assembly85 Sealing Elements: Oil Pan Gasket,...C Seal - Tube Assembly, Oil, Turbo Inlet13 85 -N0101- 03 1 PIA Tube Assembly-Oil, ...DCompression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet13 85 -N0101- 04 4 PIA Tube Assembly-Oil, ...99 MiscellaneousF Oil - Synthetic13 99 -N0101- 08 11Diff.$4.00 $0.00 $0.004.00$-$ -$ -$ -$-$-$4.00$100 Engine AssemblyA Assemble Additional or Modified Lubrication Subsystem Parts to Engine1Diff.$0.93 $1.46 $2.635.02$-$ -$ -$ -$-$-$5.02$$12.63 5.30$ 11.74$29.67$0.14$ 2.13$ 1.78$ 0.51$4.55$0.24$34.46$NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMName/Description Part Number

Item Subsystem Sub-Subsystem AssemblyManufacturingTotalManufacturingCost(Component/Assembly)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-13, 29 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.13Printed: 12/9/200913 Lubrication Subsystem (e.g.Oil Pans, Sumps)02 Oil PumpsA Oil Pump Assembly13 02 -N0101- 01 1 1 Diff.06 Oil FilterA Filter Cooler Assembly - Oil (Includes Seals)13 06 -N0101- 01 11Diff.70 Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure, Low Pressure.A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet toTurbocharger 13 70 -N0101- 01 1(Shipped PIA to Filter/CoolerAssembly, although showingcost broke out separately)1FullB Tube Assembly - Oil, Turbo to Engine Block (PistonSquirter's)13 70 -N0101- 02 11Full80 Boltings & ClampsC Bolt - Filter Cooler Assembly13 80 -N0101- 03 4 PIA to Engine AssemblyD Bolt - Tube Assembly , Oil, Turbo Inlet13 80 -N0101- 09 1 PIA to Engine AssemblyE Clamp - Tube Assembly, Oil, Cooler/Filter Outlet13 80 -N0101- 05 1 PIA Tube Assembly-Oil, ...F Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet13 80 -N0101- 06 2 PIA to Engine Assembly85 Sealing Elements: Oil Pan Gasket,...C Seal - Tube Assembly, Oil, Turbo Inlet13 85 -N0101- 03 1 PIA Tube Assembly-Oil, ...DCompression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet13 85 -N0101- 04 4 PIA Tube Assembly-Oil, ...99 MiscellaneousF Oil - Synthetic13 99 -N0101- 08 11Diff.100 Engine AssemblyA Assemble Additional or Modified Lubrication Subsystem Parts to Engine1Diff.NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Name/Description Part Number

Item Subsystem Sub-Subsystem AssemblyGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$NetComponent/AssemblyCost Impact toOEMBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)TotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)ManufacturingFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-13, 30 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.13Printed: 12/9/200913 Lubrication Subsystem (e.g.Oil Pans, Sumps)02 Oil PumpsA Oil Pump Assembly13 02 -N0101- 01 1 1 Diff.06 Oil FilterA Filter Cooler Assembly - Oil (Includes Seals)13 06 -N0101- 01 11Diff.70 Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure, Low Pressure.A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet toTurbocharger 13 70 -N0101- 01 1(Shipped PIA to Filter/CoolerAssembly, although showingcost broke out separately)1FullB Tube Assembly - Oil, Turbo to Engine Block (PistonSquirter's)13 70 -N0101- 02 11Full80 Boltings & ClampsC Bolt - Filter Cooler Assembly13 80 -N0101- 03 4 PIA to Engine AssemblyD Bolt - Tube Assembly , Oil, Turbo Inlet13 80 -N0101- 09 1 PIA to Engine AssemblyE Clamp - Tube Assembly, Oil, Cooler/Filter Outlet13 80 -N0101- 05 1 PIA Tube Assembly-Oil, ...F Bolt - Tube Assembly , Oil, Turbo Outlet & Block Inlet13 80 -N0101- 06 2 PIA to Engine Assembly85 Sealing Elements: Oil Pan Gasket,...C Seal - Tube Assembly, Oil, Turbo Inlet13 85 -N0101- 03 1 PIA Tube Assembly-Oil, ...DCompression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet13 85 -N0101- 04 4 PIA Tube Assembly-Oil, ...99 MiscellaneousF Oil - Synthetic13 99 -N0101- 08 11Diff.100 Engine AssemblyA Assemble Additional or Modified Lubrication Subsystem Parts to Engine1Diff.NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Name/Description Part Number

Item Subsystem Sub-Subsystem AssemblyGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$3.08 -$ -$3.08$0.02$ 0.22$ 0.25$ 0.12$0.61$-$3.69$$2.93 2.23$ 5.31$10.48$0.10$ 1.44$ 1.21$ 0.38$3.13$0.16$13.78$$1.27 0.80$ 1.59$3.66$0.01$ 0.23$ 0.16$ -$0.40$0.03$4.09$0.42$ 0.81$ 2.20$3.43$0.01$ 0.24$ 0.16$ -$0.41$0.06$3.90$4.00$ -$ -$4.00$-$ -$ -$ -$-$-$4.00$$0.93 1.46$ 2.63$5.02$-$ -$ -$ -$-$-$5.02$12.63$ 5.30$ 11.74$29.67$0.14$ 2.13$ 1.78$ 0.51$4.55$0.24$34.46$MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)TotalManufacturingCost(Component/Assembly)ManufacturingFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-13, 31 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.14Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D14 Cooling Subsystem01 Water PumpsB Pump- Auxiliary Coolant, Electric 14 01 -N0101- 02 1Full 13.90$ 1.63$ 4.22$19.75$0.18$ 1.82$ 2.07$ 1.03$5.10$0.06$24.91$70 Pipes, Hoses, DuctingB Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 14 70 -N0101- 02 1Full1.02$ 1.10$ 2.01$4.13$0.00$ 0.25$ 0.17$ -$0.41$0.04$4.59$C Hose Assembly - Auxiliary Pump to Turbo 14 70 -N0101- 03 1Full0.72$ 0.87$ 1.85$3.45$0.01$ 0.21$ 0.14$ -$0.36$-$3.81$D14 70 -N0101- 04 1Full0.85$ 0.59$ 0.43$1.88$0.01$ 0.11$ 0.08$ -$0.19$-$2.07$75 BracketsA14 75 -N0101- 01 1 PIA to Aux. Pump80 Boltings & ClampsD14 80 -N0101- 04 1 PIA to Hose AssemblyE14 80 -N0101- 05 1 PIA to Engine AssemblyF14 80 -N0101- 06 2 PIA to Engine AssemblyG14 80 -N0101- 07 2 PIA to Engine AssemblyI14 80 -N0101- 09 1 PIA to Hose AssemblyJ14 80 -N0101- 10 2 PIA to Hose AssemblyM14 80 -N0101- 13 4 PIA to Engine Assembly100 Engine AssemblyAMod0.74$ 1.94$ 3.50$6.19$-$ -$ -$ -$-$-$6.19$$17.24 6.14$ 12.02$35.40$0.20$ 2.39$ 2.45$ 1.03$6.06$0.10$41.56$NOTES:1.Assembly Additional or Revised Cooling Subsystem parts toEngineClamp - Hose, Auxiliary Pump to TurboClamp - Hose, Oil Filter Cooler Assembly to AuxiliaryPumpWasher Banjo Bolt - Hose Coolant Inlet & OutletTurboClamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ThermoBolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKTMountBolt-Hose, Inlet and Outlet @ TurboBolt - Auxiliary Pump to Oil Filter Cooler BracketAssemblyMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)Bracket Subassembly - Auxiliary Pump to Oil Filter/CoolerAss'yHose Assembly - Oil Filer/Cooler Ass'y to AuxiliaryPumpManufacturingTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-14, 32 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.14Printed: 12/9/200914 Cooling Subsystem01 Water PumpsB Pump- Auxiliary Coolant, Electric 14 01 -N0101- 02 1Full70 Pipes, Hoses, DuctingB Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 14 70 -N0101- 02 1FullC Hose Assembly - Auxiliary Pump to Turbo 14 70 -N0101- 03 1FullD14 70 -N0101- 04 1Full75 BracketsA14 75 -N0101- 01 1 PIA to Aux. Pump80 Boltings & ClampsD14 80 -N0101- 04 1 PIA to Hose AssemblyE14 80 -N0101- 05 1 PIA to Engine AssemblyF14 80 -N0101- 06 2 PIA to Engine AssemblyG14 80 -N0101- 07 2 PIA to Engine AssemblyI14 80 -N0101- 09 1 PIA to Hose AssemblyJ14 80 -N0101- 10 2 PIA to Hose AssemblyM14 80 -N0101- 13 4 PIA to Engine Assembly100 Engine AssemblyAModNOTES:1.Assembly Additional or Revised Cooling Subsystem parts toEngineClamp - Hose, Auxiliary Pump to TurboClamp - Hose, Oil Filter Cooler Assembly to AuxiliaryPumpWasher Banjo Bolt - Hose Coolant Inlet & OutletTurboClamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ThermoBolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKTMountBolt-Hose, Inlet and Outlet @ TurboBolt - Auxiliary Pump to Oil Filter Cooler BracketAssembly

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Bracket Subassembly - Auxiliary Pump to Oil Filter/CoolerAss'yHose Assembly - Oil Filer/Cooler Ass'y to AuxiliaryPumpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)ManufacturingBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-14, 33 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.14Printed: 12/9/200914 Cooling Subsystem01 Water PumpsB Pump- Auxiliary Coolant, Electric 14 01 -N0101- 02 1Full70 Pipes, Hoses, DuctingB Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 14 70 -N0101- 02 1FullC Hose Assembly - Auxiliary Pump to Turbo 14 70 -N0101- 03 1FullD14 70 -N0101- 04 1Full75 BracketsA14 75 -N0101- 01 1 PIA to Aux. Pump80 Boltings & ClampsD14 80 -N0101- 04 1 PIA to Hose AssemblyE14 80 -N0101- 05 1 PIA to Engine AssemblyF14 80 -N0101- 06 2 PIA to Engine AssemblyG14 80 -N0101- 07 2 PIA to Engine AssemblyI14 80 -N0101- 09 1 PIA to Hose AssemblyJ14 80 -N0101- 10 2 PIA to Hose AssemblyM14 80 -N0101- 13 4 PIA to Engine Assembly100 Engine AssemblyAModNOTES:1.Assembly Additional or Revised Cooling Subsystem parts toEngineClamp - Hose, Auxiliary Pump to TurboClamp - Hose, Oil Filter Cooler Assembly to AuxiliaryPumpWasher Banjo Bolt - Hose Coolant Inlet & OutletTurboClamp-Hose Thermo/Coolant Valve Ass'y to Turbo @ThermoBolt-Hose Ass'yThermo/Coolant Valve to Turbo, BRKTMountBolt-Hose, Inlet and Outlet @ TurboBolt - Auxiliary Pump to Oil Filter Cooler BracketAssembly

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Bracket Subassembly - Auxiliary Pump to Oil Filter/CoolerAss'yHose Assembly - Oil Filer/Cooler Ass'y to AuxiliaryPumpTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$13.90 1.63$ 4.22$19.75$0.18$ 1.82$ 2.07$ 1.03$5.10$0.06$24.91$$1.02 1.10$ 2.01$4.13$0.00$ 0.25$ 0.17$ -$0.41$0.04$4.59$0.72$ 0.87$ 1.85$3.45$0.01$ 0.21$ 0.14$ -$0.36$-$3.81$$0.85 0.59$ 0.43$1.88$0.01$ 0.11$ 0.08$ -$0.19$-$2.07$0.74$ 1.94$ 3.50$6.19$-$ -$ -$ -$-$-$6.19$17.24$ 6.14$ 12.02$35.40$0.20$ 2.39$ 2.45$ 1.03$6.06$0.10$41.56$TotalManufacturingCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)ManufacturingMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-14, 34 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.15Printed: 12/9/2009DRAFTMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D15 Induction Air Charging Subsystem01 Turbo Chargers (Assemblies)A Turbo Charger Assembly15 01 -N0101- 01 1Full 49.30$ 26.79$ 33.75$109.84$6.34$ 14.26$ 15.29$ 6.01$41.90$0.11$151.85$A1 Waste Gate Anti Surge Control Valve15 01 -N0101- 02 1 PIA05 Heat ExchangerA Cooler Assembly - Charged Air15 05 -N0101- 01 1Full 6.91$ 2.85$ 6.44$16.20$0.08$ 0.97$ 0.97$ 0.32$2.35$0.10$18.65$70 Pipes, Hoses, DuctingA Tube Assembly - Turbo Waste Gate Pneumatic Control15 70 -N0101- 03 1Full 1.93$ 1.12$ 2.36$5.41$0.02$ 0.32$ 0.22$ 0.05$0.61$0.10$6.12$B Tube Ass'y w. Vehicle Tie Down Resonator, Air CoolerInlet15 70 -N0101- 19 1Full 4.98$ 1.61$ 2.16$8.75$0.03$ 0.53$ 0.35$ 0.09$0.99$0.08$9.82$BI Tube - Turbo Outlet to Vehicle Mount Coupler15 70 -N0101- 20 1 PIAB2 Coupler - Turbo Outlet Tube to Cooler Intake Tube15 70 -N0101- 21 1 PIAB3 Tube - Coupler to Charge Air Cooler15 70 -N0101- 22 1 PIAC Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet15 70 N0101 30 1Full 10.83$ 2.65$ 3.32$16.81$0.05$ 1.01$ 0.67$ 0.17$1.90$0.06$18.76$C1 Tube - Charge Air Cooler Outlet15 70 -N0101- 01 1 PIAC2 Tube - Formed, Charge Air Cooler Tube Outlet15 70 -N0101- 31 1 PIAD Tube - Elbow, Upper to Charged Air Coupler By-Pass15 70 -N0101- 40 1Full 2.26$ 0.58$ 1.08$3.92$0.01$ 0.24$ 0.16$ 0.04$0.44$0.03$4.39$E Tube - Coupler Y Branch to By-Pass15 70 -N0101- 41 1 (E,F,G, H Combined) Full 5.48$ 2.48$ 3.77$11.73$0.04$ 0.70$ 0.47$ 0.12$1.33$0.07$13.12$F Tube - Elbow Coupler By-Pass to Throttle Body15 70 -N0101- 42 1 PIAG Tube - Charged Air Bypass to Silencer15 70 -N0101- 43 1 PIAH Tube - Flex Elbow, Silencer to Environment15 70 -N0101- 44 1 PIA75 BracketsA Bracket - Support, Turbo Assembly15 75 -N0101- 01 1Full 1.07$ 0.15$ 0.39$1.61$0.00$ 0.10$ 0.06$ -$0.17$0.06$1.84$80 Boltings, Clamps, Misc FasteningC Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 03 1 PIA Engine AssemblyD Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 04 1 PIA Engine AssemblyE Bolt - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 05 2 PIA Engine AssemblyF Nut - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 06 1 PIA Engine AssemblyH Clamp - Tube, Large, Turbo to Throttle Body15 80 -N0101- 08 9 PIA To HosesI Bolt - Tube, Charge Air Cooler to Vehicle15 80 -N0101- 09 2 PIA Engine AssemblyJ Screw - Sensor, Charge Air Temperature15 80 -N0101- 10 1 PIA Tube Charged AirL Clamp - Tubing Charged Air By-Pass15 80 -N0101- 12 3 PIA To HosesM Retainer - Vehicle, Charged Air By-Pass Elbow15 80 -N0101- 13 1 PIA Tube-Flex Elbow...99 MiscellaneousA Vacuum Reservoir - Turbo Waste Gate15 99 -N0101- 01 1Full 1.08$ 0.34$ 0.63$2.05$0.01$ 0.22$ 0.18$ 0.05$0.48$0.10$2.63$B Value - Thrust Control, Turbo Waste Gate PneumaticControl15 99 -N0101- 02 1Full 5.19$ -$ -$5.19$0.03$ 0.34$ 0.31$ 0.13$0.80$0.02$6.02$C Sensor - Intake Temperature, Outlet Charged Air Cooler15 99 -N0101- 03 1 PIA Tube Charged AirD Baffle - Charge Air By-Pass15 99 -N0101- 04 1 PIA Tube-Flex Elbow...100 Vehicle/Engine AssemblyA Engine and Vehicle Asssembly of Air Induction ComponentsFull 1.14$ 9.81$ 14.75$25.70$-$ -$ -$ -$-$-$25.70$$90.16 48.38$ 68.66$207.21$6.61$ 18.68$ 18.69$ 6.98$50.97$0.71$258.89$NOTES:1.= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturingdifferentials are accounted for in the quote sheetof the competing technology.MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/ Assembly)NetComponent/AssemblyCost Impactto OEMManufacturingTotalManufacturingCost(Component/Assembly)

Item Subsystem Sub-Subsystem AssemblyGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part NumberNEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-15, 35 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.15Printed: 12/9/2009DRAFT15 Induction Air Charging Subsystem01 Turbo Chargers (Assemblies)A Turbo Charger Assembly15 01 -N0101- 01 1FullA1 Waste Gate Anti Surge Control Valve15 01 -N0101- 02 1 PIA05 Heat ExchangerA Cooler Assembly - Charged Air15 05 -N0101- 01 1Full70 Pipes, Hoses, DuctingA Tube Assembly - Turbo Waste Gate Pneumatic Control15 70 -N0101- 03 1FullB Tube Ass'y w. Vehicle Tie Down Resonator, Air CoolerInlet15 70 -N0101- 19 1FullBI Tube - Turbo Outlet to Vehicle Mount Coupler15 70 -N0101- 20 1 PIAB2 Coupler - Turbo Outlet Tube to Cooler Intake Tube15 70 -N0101- 21 1 PIAB3 Tube - Coupler to Charge Air Cooler15 70 -N0101- 22 1 PIAC Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet15 70 N0101 30 1FullC1 Tube - Charge Air Cooler Outlet15 70 -N0101- 01 1 PIAC2 Tube - Formed, Charge Air Cooler Tube Outlet15 70 -N0101- 31 1 PIAD Tube - Elbow, Upper to Charged Air Coupler By-Pass15 70 -N0101- 40 1FullE Tube - Coupler Y Branch to By-Pass15 70 -N0101- 41 1 (E,F,G, H Combined) FullF Tube - Elbow Coupler By-Pass to Throttle Body15 70 -N0101- 42 1 PIAG Tube - Charged Air Bypass to Silencer15 70 -N0101- 43 1 PIAH Tube - Flex Elbow, Silencer to Environment15 70 -N0101- 44 1 PIA75 BracketsA Bracket - Support, Turbo Assembly15 75 -N0101- 01 1Full80 Boltings, Clamps, Misc FasteningC Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 03 1 PIA Engine AssemblyD Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 04 1 PIA Engine AssemblyE Bolt - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 05 2 PIA Engine AssemblyF Nut - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 06 1 PIA Engine AssemblyH Clamp - Tube, Large, Turbo to Throttle Body15 80 -N0101- 08 9 PIA To HosesI Bolt - Tube, Charge Air Cooler to Vehicle15 80 -N0101- 09 2 PIA Engine AssemblyJ Screw - Sensor, Charge Air Temperature15 80 -N0101- 10 1 PIA Tube Charged AirL Clamp - Tubing Charged Air By-Pass15 80 -N0101- 12 3 PIA To HosesM Retainer - Vehicle, Charged Air By-Pass Elbow15 80 -N0101- 13 1 PIA Tube-Flex Elbow...99 MiscellaneousA Vacuum Reservoir - Turbo Waste Gate15 99 -N0101- 01 1FullB Value - Thrust Control, Turbo Waste Gate PneumaticControl15 99 -N0101- 02 1FullC Sensor - Intake Temperature, Outlet Charged Air Cooler15 99 -N0101- 03 1 PIA Tube Charged AirD Baffle - Charge Air By-Pass15 99 -N0101- 04 1 PIA Tube-Flex Elbow...100 Vehicle/Engine AssemblyA Engine and Vehicle Asssembly of Air Induction ComponentsFullNOTES:1.= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturingdifferentials are accounted for in the quote sheetof the competing technology.

Item Subsystem Sub-Subsystem AssemblyGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$NetComponent/AssemblyCost Impactto OEMManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/ Assembly)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-15, 36 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.15Printed: 12/9/2009DRAFT15 Induction Air Charging Subsystem01 Turbo Chargers (Assemblies)A Turbo Charger Assembly15 01 -N0101- 01 1FullA1 Waste Gate Anti Surge Control Valve15 01 -N0101- 02 1 PIA05 Heat ExchangerA Cooler Assembly - Charged Air15 05 -N0101- 01 1Full70 Pipes, Hoses, DuctingA Tube Assembly - Turbo Waste Gate Pneumatic Control15 70 -N0101- 03 1FullB Tube Ass'y w. Vehicle Tie Down Resonator, Air CoolerInlet15 70 -N0101- 19 1FullBI Tube - Turbo Outlet to Vehicle Mount Coupler15 70 -N0101- 20 1 PIAB2 Coupler - Turbo Outlet Tube to Cooler Intake Tube15 70 -N0101- 21 1 PIAB3 Tube - Coupler to Charge Air Cooler15 70 -N0101- 22 1 PIAC Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet15 70 N0101 30 1FullC1 Tube - Charge Air Cooler Outlet15 70 -N0101- 01 1 PIAC2 Tube - Formed, Charge Air Cooler Tube Outlet15 70 -N0101- 31 1 PIAD Tube - Elbow, Upper to Charged Air Coupler By-Pass15 70 -N0101- 40 1FullE Tube - Coupler Y Branch to By-Pass15 70 -N0101- 41 1 (E,F,G, H Combined) FullF Tube - Elbow Coupler By-Pass to Throttle Body15 70 -N0101- 42 1 PIAG Tube - Charged Air Bypass to Silencer15 70 -N0101- 43 1 PIAH Tube - Flex Elbow, Silencer to Environment15 70 -N0101- 44 1 PIA75 BracketsA Bracket - Support, Turbo Assembly15 75 -N0101- 01 1Full80 Boltings, Clamps, Misc FasteningC Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 03 1 PIA Engine AssemblyD Bolt - Bracket Support, Turbo Assembly15 80 -N0101- 04 1 PIA Engine AssemblyE Bolt - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 05 2 PIA Engine AssemblyF Nut - Pressure Reservoir, Turbo Waste Gate15 80 -N0101- 06 1 PIA Engine AssemblyH Clamp - Tube, Large, Turbo to Throttle Body15 80 -N0101- 08 9 PIA To HosesI Bolt - Tube, Charge Air Cooler to Vehicle15 80 -N0101- 09 2 PIA Engine AssemblyJ Screw - Sensor, Charge Air Temperature15 80 -N0101- 10 1 PIA Tube Charged AirL Clamp - Tubing Charged Air By-Pass15 80 -N0101- 12 3 PIA To HosesM Retainer - Vehicle, Charged Air By-Pass Elbow15 80 -N0101- 13 1 PIA Tube-Flex Elbow...99 MiscellaneousA Vacuum Reservoir - Turbo Waste Gate15 99 -N0101- 01 1FullB Value - Thrust Control, Turbo Waste Gate PneumaticControl15 99 -N0101- 02 1FullC Sensor - Intake Temperature, Outlet Charged Air Cooler15 99 -N0101- 03 1 PIA Tube Charged AirD Baffle - Charge Air By-Pass15 99 -N0101- 04 1 PIA Tube-Flex Elbow...100 Vehicle/Engine AssemblyA Engine and Vehicle Asssembly of Air Induction ComponentsFullNOTES:1.= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturingdifferentials are accounted for in the quote sheetof the competing technology.

Item Subsystem Sub-Subsystem AssemblyGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D49.30$ 26.79$ 33.75$109.84$6.34$ 14.26$ 15.29$ 6.01$41.90$0.11$151.85$6.91$ 2.85$ 6.44$16.20$0.08$ 0.97$ 0.97$ 0.32$2.35$0.10$18.65$1.93$ 1.12$ 2.36$5.41$0.02$ 0.32$ 0.22$ 0.05$0.61$0.10$6.12$4.98$ 1.61$ 2.16$8.75$0.03$ 0.53$ 0.35$ 0.09$0.99$0.08$9.82$10.83$ 2.65$ 3.32$16.81$0.05$ 1.01$ 0.67$ 0.17$1.90$0.06$18.76$2.26$ 0.58$ 1.08$3.92$0.01$ 0.24$ 0.16$ 0.04$0.44$0.03$4.39$5.48$ 2.48$ 3.77$11.73$0.04$ 0.70$ 0.47$ 0.12$1.33$0.07$13.12$1.07$ 0.15$ 0.39$1.61$0.00$ 0.10$ 0.06$ -$0.17$0.06$1.84$1.08$ 0.34$ 0.63$2.05$0.01$ 0.22$ 0.18$ 0.05$0.48$0.10$2.63$5.19$ -$ -$5.19$0.03$ 0.34$ 0.31$ 0.13$0.80$0.02$6.02$1.14$ 9.81$ 14.75$25.70$-$ -$ -$ -$-$-$25.70$90.16$ 48.38$ 68.66$207.21$6.61$ 18.68$ 18.69$ 6.98$50.97$0.71$258.89$TotalManufacturingCost(Component/Assembly)ManufacturingINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impactto OEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-15, 37 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.17Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D17 Breather Subsystem02 Oil/Air SeparatorA PCV ASSEMBLY - (Built into Cylinder Head Cover)17 02 - N0101 - 00 11Diff1.35$ 0.37$ 1.49$3.21$0.03$ 0.42$ 0.39$ 0.12$0.96$-$4.17$A1 Valve - Non Return Intake Hose Side17 02 - N0101 - 01 1A2 Separator - Cyclone17 02 - N0101 - 10 1A3 Valve - Pressure Control17 02 - N0101 - 20 1A4 Valve - Oil Drain17 02 - N0101 - 30 1A5 Valve - Non Return Intake Manifold Side17 02 - N0101 - 40 1100 Engine AssemblyA Engine Assembly Additions/Modifications for Breather SubsystemNA-$ -$ -$-$-$ -$ -$ -$-$-$-$$1.35 0.37$ 1.49$3.21$0.03$ 0.42$ 0.39$ 0.12$0.96$-$4.17$NOTES:1.ManufacturingTotalManufacturingCost(Component/Assembly)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem AssemblyMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMNEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-17, 38 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.17Printed: 12/9/200917 Breather Subsystem02 Oil/Air SeparatorA PCV ASSEMBLY - (Built into Cylinder Head Cover)17 02 - N0101 - 00 11DiffA1 Valve - Non Return Intake Hose Side17 02 - N0101 - 01 1A2 Separator - Cyclone17 02 - N0101 - 10 1A3 Valve - Pressure Control17 02 - N0101 - 20 1A4 Valve - Oil Drain17 02 - N0101 - 30 1A5 Valve - Non Return Intake Manifold Side17 02 - N0101 - 40 1100 Engine AssemblyA Engine Assembly Additions/Modifications for Breather SubsystemNANOTES:1.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$ -$-$ -$ -$ -$ -$ -$ -$ -$ -$-$ -$ -$-$-$ -$ -$ -$-$-$-$ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-17, 39 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.17Printed: 12/9/200917 Breather Subsystem02 Oil/Air SeparatorA PCV ASSEMBLY - (Built into Cylinder Head Cover)17 02 - N0101 - 00 11DiffA1 Valve - Non Return Intake Hose Side17 02 - N0101 - 01 1A2 Separator - Cyclone17 02 - N0101 - 10 1A3 Valve - Pressure Control17 02 - N0101 - 20 1A4 Valve - Oil Drain17 02 - N0101 - 30 1A5 Valve - Non Return Intake Manifold Side17 02 - N0101 - 40 1100 Engine AssemblyA Engine Assembly Additions/Modifications for Breather SubsystemNANOTES:1.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Subassembly ComponentName/Description Part Number

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$1.35 0.37$ 1.49$3.21$0.03$ 0.42$ 0.39$ 0.12$0.96$-$4.17$$0.00 -$ -$-$-$ -$ -$ -$-$-$-$1.35$ 0.37$ 1.49$3.21$0.03$ 0.42$ 0.39$ 0.12$0.96$-$4.17$TotalManufacturingCost(Component/Assembly)ManufacturingINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-17, 40 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.60Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D60 Engine Management, Engine Electronic and Electrical Subsystems02 Engine Management Systems, Engine Electronic SystemsA Power Train Control Module (PCM) Assembly - Hardware60 02 - N0101 - 01 1Diff. 40.00$ -$ -$40.00$-$ -$ -$ -$-$-$40.00$B Power Train Control Module (PCM) Assembly - Software 60 02 - N0101 - 50 1Included in Indirect Cost(IC)MultiplierNA $0.00 $0.00 $0.00-$-$ -$ -$ -$-$-$-$03Diff. $12.13 $0.00 $0.0012.13$-$ -$ -$ -$-$-$12.13$A Ignition Coil Assembly - Single Spark60 03 - N0101 - 01 4 PIA to Engine AssemblyC Wire Harness Assembly #1 - Engine, Main60 03 - N0101 - 30 1 PIA to Engine Assembly100 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)A Assembly Modification & Addition to Engine Management & Electrical SubsystemsAdded Electrical Connections Diff.-$ 1.60$ 2.88$4.48$-$ -$ -$ -$-$-$4.48$$52.13 1.60$ 2.88$56.61$-$ -$ -$ -$-$-$56.61$NOTES:1.NetComponent/AssemblyCost Impact toOEM

Subassembly ComponentName/Description Part NumberTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem AssemblyNEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils,Sockets)ManufacturingTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-60, 41 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.60Printed: 12/9/200960 Engine Management, Engine Electronic and Electrical Subsystems02 Engine Management Systems, Engine Electronic SystemsA Power Train Control Module (PCM) Assembly - Hardware60 02 - N0101 - 01 1Diff.B Power Train Control Module (PCM) Assembly - Software 60 02 - N0101 - 50 1Included in Indirect Cost(IC)MultiplierNA03Diff.A Ignition Coil Assembly - Single Spark60 03 - N0101 - 01 4 PIA to Engine AssemblyC Wire Harness Assembly #1 - Engine, Main60 03 - N0101 - 30 1 PIA to Engine Assembly100 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)A Assembly Modification & Addition to Engine Management & Electrical SubsystemsAdded Electrical Connections Diff.NOTES:1. Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor 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) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-60, 42 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.60Printed: 12/9/200960 Engine Management, Engine Electronic and Electrical Subsystems02 Engine Management Systems, Engine Electronic SystemsA Power Train Control Module (PCM) Assembly - Hardware60 02 - N0101 - 01 1Diff.B Power Train Control Module (PCM) Assembly - Software 60 02 - N0101 - 50 1Included in Indirect Cost(IC)MultiplierNA03Diff.A Ignition Coil Assembly - Single Spark60 03 - N0101 - 01 4 PIA to Engine AssemblyC Wire Harness Assembly #1 - Engine, Main60 03 - N0101 - 30 1 PIA to Engine Assembly100 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)A Assembly Modification & Addition to Engine Management & Electrical SubsystemsAdded Electrical Connections Diff.NOTES:1. Subassembly ComponentName/Description Part NumberGENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor 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) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$40.00 -$ -$40.00$-$ -$ -$ -$-$-$40.00$$0.00 -$ -$-$-$ -$ -$ -$-$-$-$$12.13 -$ -$12.13$-$ -$ -$ -$-$-$12.13$$0.00 1.60$ 2.88$4.48$-$ -$ -$ -$-$-$4.48$52.13$ 1.60$ 2.88$56.61$-$ -$ -$ -$-$-$56.61$TotalManufacturingCost(Component/Assembly)ManufacturingINCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-60, 43 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.70Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D70 Accessories Subsystem (Starter Engines, Generators, Power Steering Pumps, etc)04 Vacuum PumpsA Vacuum Pump Assembly70 04 -N0101- 01 11Full3.31$ 1.81$ 6.56$11.69$0.09$ 1.41$ 1.15$ 0.32$2.96$0.09$14.74$80 BoltingsA Bolt - Vacuum Pump70 80 -N0101- 01 2 PIA Engine Assembly1Full100 Engine AssemblyA Engine Assembly Additions/Modifications for Accessory Subsystem1Full0.13$ 0.74$ 1.34$2.20$-$ -$ -$ -$-$-$2.20$$3.44 2.55$ 7.90$13.89$0.09$ 1.41$ 1.15$ 0.32$2.96$0.09$16.95$NOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.ManufacturingTotalManufacturingCost(Component/Assembly)NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberMarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-70, 44 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.70Printed: 12/9/200970 Accessories Subsystem (Starter Engines, Generators, Power Steering Pumps, etc)04 Vacuum PumpsA Vacuum Pump Assembly70 04 -N0101- 01 11Full80 BoltingsA Bolt - Vacuum Pump70 80 -N0101- 01 2 PIA Engine Assembly1Full100 Engine AssemblyA Engine Assembly Additions/Modifications for Accessory Subsystem1FullNOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$ -$ -$ -$ -$ -$-$ -$ -$ -$ -$ -$ -$ -$-$ -$ -$-$-$ -$ -$ -$-$-$-$BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-70, 45 of 46Author: G. Kolwich(248)373-6000 Ext. 2411SUBSYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Light-Duty Technology Cost StudyEP-C-07-069 WA1-3APPENDIX H.1.70Printed: 12/9/200970 Accessories Subsystem (Starter Engines, Generators, Power Steering Pumps, etc)04 Vacuum PumpsA Vacuum Pump Assembly70 04 -N0101- 01 11Full80 BoltingsA Bolt - Vacuum Pump70 80 -N0101- 01 2 PIA Engine Assembly1Full100 Engine AssemblyA Engine Assembly Additions/Modifications for Accessory Subsystem1FullNOTES:1.= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.GENERAL PART INFORMATIONQTY/P.TNotes LevelFullMod.Diff.

Item Subsystem Sub-Subsystem Assembly Subassembly ComponentName/Description Part NumberTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D$3.31 1.81$ 6.56$11.69$0.09$ 1.41$ 1.15$ 0.32$2.96$0.09$14.74$0.13$ 0.74$ 1.34$2.20$-$ -$ -$ -$-$-$2.20$3.44$ 2.55$ 7.90$13.89$0.09$ 1.41$ 1.15$ 0.32$2.96$0.09$16.95$MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/Assembly)NetComponent/AssemblyCost Impact toOEMBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)TotalManufacturingCost(Component/Assembly)ManufacturingFile:SUBSYS_CMAT-H.1.xlsEPA Contract:EP-C-07-069 WA1-3Appendix H.1-70, 46 of 46Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX H.2 SYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Case Study #0101APPENDIX H.2Printed: 12/9/2009Material Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D02No Modifications orAdditions Required1 NA03 Crank Drive SubsystemLast Updated 5/20/091 Mod.(4.09)$0.39$ 4.15$0.46$0.28$(0.37)$ (0.51)$0.14$(0.46)$-$0.00$04 Counter Balance SubsystemLast Updated 5/20/091 TBD-$ -$ -$-$-$ -$ -$ -$-$-$-$05 Cylinder Block SubsystemLast Updated 5/20/091 Mod.(7.59)$1.36$ 5.78$(0.46)$(0.53)$0.83$ 0.56$ -$0.86$0.04$0.44$06 Cylinder Head SubsystemLast Updated 5/20/091 Mod.5.57$ 0.81$ 6.94$13.32$1.80$ 0.65$ 0.71$ 0.04$3.20$0.03$16.55$07 Valve Train SubsystemLast Updated 5/20/091 Mod $8.40 -$ -$8.40$0.05$ 0.59$ 0.68$ 0.34$1.65$-$10.06$08 Timing Drive SubsystemLast Updated 5/20/091 Mod $1.60 -$ -$1.60$-$ -$ -$ -$-$-$1.60$09 Accessory Drive SubsystemNo Modifications orAdditions Required1 NA10 Intake SubsystemLast Updated 5/20/091 NA($10.66) (0.01)$ (0.10)$(10.78)$(0.05)$ (0.70)$ (0.65)$ (0.27)$(1.67)$(0.28)$(12.73)$11 Fuel Induction SubsystemLast Update 5/20/091 Add & Mod $37.25 17.41$ 62.87$117.53$1.23$ 12.30$ 12.25$ 4.67$30.44$0.24$148.21$12 Exhaust SubsystemLast Updated 5/20/091 Mod $27.24 0.11$ 3.09$30.44$2.97$ 1.97$ 1.79$ 0.71$7.44$(0.12)$37.77$13Last Updated 5/20/091 Add & Mod $12.63 5.30$ 11.74$29.67$0.14$ 2.13$ 1.78$ 0.51$4.55$0.24$34.46$14 Cooling SubsystemLast Updated 5/20/091 Add$17.24 6.14$ 12.02$35.40$0.20$ 2.39$ 2.45$ 1.03$6.06$0.10$41.56$15 Induction Air Charging SubsystemLast Updated 5/20/091 Add $90.16 48.38$ 68.66$207.21$6.61$ 18.68$ 18.69$ 6.98$50.97$0.71$258.89$16Subsystem does notexist on either Base orNew TechnologyPackage.1 NA17 Breather SubsystemLast Updated 5/20/091 Mod$1.35 0.37$ 1.49$3.21$0.03$ 0.42$ 0.39$ 0.12$0.96$-$4.17$60Last Updated 5/20/091 Mod$52.13 1.60$ 2.88$56.61$-$ -$ -$ -$-$-$56.61$70Last Updated 4/2/091 Add.$3.44 2.55$ 7.90$13.89$0.09$ 1.41$ 1.15$ 0.32$2.96$0.09$16.95$234.68$ 84.41$ 187.40$506.50$12.81$ 40.28$ 39.29$ 14.59$106.97$1.06$614.53$NOTES:1.MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/ Assembly)NetComponent/AssemblyCost Impact toOEMTotalManufacturingCost(Component/Assembly)

Item SubsystemGENERAL PART INFORMATIONNotes LevelAddition orModification= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.NEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, Turbo, DI w. dVVT(Study Case# N0101)Engine Management Systems,Engine Electronic Systems,Electrical SubsystemsAccessory Subsystems (StarterEngines, Generators, PowerSteering Pumps, etc)Subsystem DescriptionEngine Frames, Mountings &Brackets SubsystemExhaust Gas Re-CirculationSubsystemLubrication Subsystems (OilPans/Sumps)ManufacturingTechnology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassFile:SYSCMAT_CS0101-H.2 -120809.xlsEPA Contract:EP-C-07-069 WA1-3H.2, Page 1 of 3Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX H.2 SYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Case Study #0101APPENDIX H.2Printed: 12/9/200902No Modifications orAdditions Required1 NA03 Crank Drive SubsystemLast Updated 5/20/091 Mod.04 Counter Balance SubsystemLast Updated 5/20/091 TBD05 Cylinder Block SubsystemLast Updated 5/20/091 Mod.06 Cylinder Head SubsystemLast Updated 5/20/091 Mod.07 Valve Train SubsystemLast Updated 5/20/091 Mod08 Timing Drive SubsystemLast Updated 5/20/091 Mod09 Accessory Drive SubsystemNo Modifications orAdditions Required1 NA10 Intake SubsystemLast Updated 5/20/091 NA11 Fuel Induction SubsystemLast Update 5/20/091 Add & Mod12 Exhaust SubsystemLast Updated 5/20/091 Mod13Last Updated 5/20/091 Add & Mod14 Cooling SubsystemLast Updated 5/20/091 Add15 Induction Air Charging SubsystemLast Updated 5/20/091 Add16Subsystem does notexist on either Base orNew TechnologyPackage.1 NA17 Breather SubsystemLast Updated 5/20/091 Mod60Last Updated 5/20/091 Mod70Last Updated 4/2/091 Add.NOTES:1. Item SubsystemGENERAL PART INFORMATIONNotes LevelAddition orModification= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Engine Management Systems,Engine Electronic Systems,Electrical SubsystemsAccessory Subsystems (StarterEngines, Generators, PowerSteering Pumps, etc)Subsystem DescriptionEngine Frames, Mountings &Brackets SubsystemExhaust Gas Re-CirculationSubsystemLubrication Subsystems (OilPans/Sumps)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A ProfitED&T-R&D-$ -$ -$-$-$ -$ -$ -$-$-$-$10.37$ 6.22$ 11.36$27.94$0.82$ 3.22$ 2.98$ 0.92$7.95$0.05$35.95$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$5.49$ 5.61$ 21.81$32.91$0.27$ 3.10$ 3.19$ 1.31$7.87$0.11$40.89$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$-$ -$ -$-$-$ -$ -$ -$-$-$-$15.86$ 11.83$ 33.17$60.86$1.10$ 6.33$ 6.16$ 2.23$15.82$0.16$76.84$TotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)TotalPackagingCost(Component/ Assembly)NetComponent/AssemblyCost Impact toOEMManufacturingBASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA, PFIw. dVVT(Study Case# B0101)File:SYSCMAT_CS0101-H.2 -120809.xlsEPA Contract:EP-C-07-069 WA1-3H.2, Page 2 of 3Author: G. Kolwich(248)373-6000 Ext. 2411APPENDIX H.2 SYSTEM COST MODEL ANALYSIS TEMPLATE (CMAT)Case Study #0101APPENDIX H.2Printed: 12/9/200902No Modifications orAdditions Required1 NA03 Crank Drive SubsystemLast Updated 5/20/091 Mod.04 Counter Balance SubsystemLast Updated 5/20/091 TBD05 Cylinder Block SubsystemLast Updated 5/20/091 Mod.06 Cylinder Head SubsystemLast Updated 5/20/091 Mod.07 Valve Train SubsystemLast Updated 5/20/091 Mod08 Timing Drive SubsystemLast Updated 5/20/091 Mod09 Accessory Drive SubsystemNo Modifications orAdditions Required1 NA10 Intake SubsystemLast Updated 5/20/091 NA11 Fuel Induction SubsystemLast Update 5/20/091 Add & Mod12 Exhaust SubsystemLast Updated 5/20/091 Mod13Last Updated 5/20/091 Add & Mod14 Cooling SubsystemLast Updated 5/20/091 Add15 Induction Air Charging SubsystemLast Updated 5/20/091 Add16Subsystem does notexist on either Base orNew TechnologyPackage.1 NA17 Breather SubsystemLast Updated 5/20/091 Mod60Last Updated 5/20/091 Mod70Last Updated 4/2/091 Add.NOTES:1. Item SubsystemGENERAL PART INFORMATIONNotes LevelAddition orModification= A highlighted Sub-subsystem, Assembly or Component rowindicates design and/or manufacturing differentials are accountedfor in the quote sheet of the competing technology.Engine Management Systems,Engine Electronic Systems,Electrical SubsystemsAccessory Subsystems (StarterEngines, Generators, PowerSteering Pumps, etc)Subsystem DescriptionEngine Frames, Mountings &Brackets SubsystemExhaust Gas Re-CirculationSubsystemLubrication Subsystems (OilPans/Sumps)Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) EngineVehicle Class:Compact/Economy 2-4 PassengerStudy Case#:N0101 & B0101 (N=New, B=Base, ) 01=Technology Package,01=Vehicle ClassMaterial Labor BurdenEnd ItemScrapSG&A Profit ED&T-R&D(4.09)$0.39$ 4.15$0.46$0.28$(0.37)$ (0.51)$0.14$(0.46)$-$0.00$(10.37)$ (6.22)$ (11.36)$(27.94)$(0.82)$ (3.22)$ (2.98)$ (0.92)$(7.95)$(0.05)$(35.95)$(7.59)$1.36$ 5.78$(0.46)$(0.53)$0.83$ 0.56$ -$0.86$0.04$0.44$5.57$ 0.81$ 6.94$13.32$1.80$ 0.65$ 0.71$ 0.04$3.20$0.03$16.55$8.40$ -$ -$8.40$0.05$ 0.59$ 0.68$ 0.34$1.65$-$10.06$1.60$ -$ -$1.60$-$ -$ -$ -$-$-$1.60$(10.66)$ (0.01)$ (0.10)$(10.78)$(0.05)$ (0.70)$ (0.65)$ (0.27)$(1.67)$(0.28)$(12.73)$31.76$ 11.80$ 41.05$84.62$0.95$ 9.20$ 9.06$ 3.36$22.58$0.13$107.32$27.24$ 0.11$ 3.09$30.44$2.97$ 1.97$ 1.79$ 0.71$7.44$(0.12)$37.77$12.63$ 5.30$ 11.74$29.67$0.14$ 2.13$ 1.78$ 0.51$4.55$0.24$34.46$17.24$ 6.14$ 12.02$35.40$0.20$ 2.39$ 2.45$ 1.03$6.06$0.10$41.56$90.16$ 48.38$ 68.66$207.21$6.61$ 18.68$ 18.69$ 6.98$50.97$0.71$258.89$1.35$ 0.37$ 1.49$3.21$0.03$ 0.42$ 0.39$ 0.12$0.96$-$4.17$52.13$ 1.60$ 2.88$56.61$-$ -$ -$ -$-$-$56.61$3.44$ 2.55$ 7.90$13.89$0.09$ 1.41$ 1.15$ 0.32$2.96$0.09$16.95$218.82$ 72.58$ 154.24$445.64$11.72$ 33.96$ 33.12$ 12.36$91.16$0.90$537.70$NetComponent/AssemblyCost Impact toOEMTotalPackagingCost(Component/Assembly)ManufacturingTotalManufacturingCost(Component/Assembly)MarkupTotal MarkupCost(Component/Assembly)INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGENEW TECHNOLOGY PACKAGE: 1.6L I4, 16V DOHC, DI, Turbo w. dVVT(Study Case# N0101)BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dVVT(Study Case# B0101)File:SYSCMAT_CS0101-H.2 -120809.xlsEPA Contract:EP-C-07-069 WA1-3H.2, Page 3 of 3Author: G. Kolwich(248)373-6000 Ext. 2411