### Page:1 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

Material Labor Burden End Item

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



# 021172 Electric Motor & Controls Subsy **stem -Electrical Housings/Covers/Support Structures**

1 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 2 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 3 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 4 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 5 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**System**

**ED&T/R&D**

**(x1000) Investment** 

**(X1000)** Markup **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)**ItemSubsystem



### Sub-Subsystem Description Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION:**

**2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**

**(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly) Tooling** 

**(x1000)** 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

6 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 7 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 8 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**- $** 

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### 9 **72 Electrical Housings/Support Structure**  **35.11 $**  **7.36**

**$ 43.28** 

**$ 85.76** 

**$ 1.12** 

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### 11 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 12 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 13 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 14 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 15 **### #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

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### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

Material Labor Burden End Item

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

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**System**

**ED&T/R&D**

**(x1000) Investment** 

**(X1000)** Markup **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)**ItemSubsystem



### Sub-Subsystem Description Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION:**

**2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**

**(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly) Tooling** 

**(x1000)** 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 



### - **$**

**-**

**$**

**-**

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**-**

**$ SUBSYSTEM ROLL-UP** 

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:3 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

Material Labor Burden End Item

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

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**System**

**ED&T/R&D**

**(x1000) Investment** 

**(X1000)** Markup **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)**ItemSubsystem



### Sub-Subsystem Description Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION:**

**2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**

**(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly) Tooling** 

**(x1000)** 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:4 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# 021172 Electric Motor & Controls Subsy **stem -Electrical Housings/Covers/Support Structures**

1 **###**

2 **###**

3 **###**

4 **###**

5 **###**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

End Item

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

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

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# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**

Manufacturing **Total**

**Manufacturing**

**Cost**

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**Assembly)** Markup

**Total Markup**

**Cost**

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**Assembly) Total** 

**Packaging**

**Cost**

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**(x1000) Investment** 

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**(x1000)**



### 6 **###**

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### 0 **n/a**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

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**$**

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### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:5 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

End Item

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

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

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(X1000) System** 

**ED&T/R&D**

**(x1000)**



### - **$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### #N/A **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:6 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

End Item

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

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

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(X1000) System** 

**ED&T/R&D**

**(x1000)**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:7 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# 021172 Electric Motor & Controls Subsy **stem -Electrical Housings/Covers/Support Structures**

1 **###**

2 **###**

3 **###**

4 **###**

5 **###**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**#N/A**

**#N/A**

**#N/A**

**#N/A**

**#N/A Investment(X1** 

**000)**



### 6 **###**

7 **###**

8 **###**

9 **72**

10 **###**

11 **###**

12 **###**

13 **###**

14 **###**

15 **###**

0 **n/a**

0 **n/a**

0 **n/a**

0 **n/a #N/A** 

**#N/A**

**#N/A**

**- $** 

**#N/A**

**#N/A**

**#N/A**

**#N/A**

**#N/A**

**#N/A**

**- $** 

**- $** 

**- $** 

**- $** 



### 0 **n/a**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:8 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Investment(X1**

**000)**

**#N/A**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:9 of 9 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Investment(X1**

**000)**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:1 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

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



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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**



# 021172 Electric Motor & Controls Subsy **stem -Electrical Housings/Covers/Support Structures**

9 **72 Electrical Housings/Support Structure**  **35.11 $**  **7.36**

**$ 43.28** 

**$ 85.76** 

**$ 1.12** 

**$ 5.28** 

**$ 4.88** 

**$ 2.02** 

**$ 13.30** 

**$**



### A Control Module Subassembly, H Housing, Main Control Unit 02 11 #

- N0502

- 01 1 Full 1 

### 5.98 $ 2.71

$ 15.29

$ **23.98**

**$** 0.84

$ 1.61

$ 1.48

$ 0.62

$ **4.54**

**$**

B H Housing Electronics Subassembly (Casting & Diversion Plate Sub) 02 11 #

- N0502

- 02 1 Full 1 

### 16.07 $ 3.96

$ 25.55

$ **45.57**

**$** 0.23

$ 3.03

$ 2.79

$ 1.15

$ **7.20**

**$**

B.1 02 11 #

- N0502

- 03 1 Full 1 Includes compoents which are PIA

to subassembly of Housing

Electronics Subassembly,

assembled by OE. 

### 6.18 $

-

$

-

$ **6.18**

**$**

-

$

-

$

-

$

-

$

**-**

**$** 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote LevelSubassemblyComponentSub-Subsystem



### Scaling

Factor

(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly)**



### Components PIA to Subassembly of H Housing,

(Assembled by VO) 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**

**(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**ItemSubsystem 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

assembled by OE.



### C H Cover Transaxle Electronics 02 11 #

- N0502

- 04 1 Full 1 

### 6.88 $ 0.70

$ 2.44

$ **10.02**

**$** 0.05

$ 0.65

$ 0.60

$ 0.25

$ **1.55**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

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

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote LevelSubassemblyComponentSub-Subsystem



### Scaling

Factor

(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**

**(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**ItemSubsystem 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:3 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

0 **n/a n/a** 



# 021172 Electric Motor & Controls Subsy **stem -Electrical Housings/Covers/Support Structures**

9 **72 Electrical Housings/Support Structure** 

A Control Module Subassembly, H Housing, Main Control Unit 02 11 #

- N0502

- 01 1 Full 1



### B H Housing Electronics Subassembly (Casting & Diversion Plate Sub) 02 11 #

- N0502

- 02 1 Full 1



### B.1 02 11 #

- N0502

- 03 1 Full 1 Includes compoents which are PIA

to subassembly of Housing

Electronics Subassembly,

assembled by OE. 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote LevelSubassemblyComponentSub-Subsystem



### Scaling

Factor

(Default =1)

Components PIA to Subassembly of H Housing,

(Assembled by VO)QTY/Subsystem 

### Notes 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**

**(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**ItemSubsystem 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**0.70 $**  **99.75**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0.09 $ **28.61**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0.30 $ **53.08**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $ **6.18**

**$**

**-**

**$**

**-**

**$**

**-**

**$ Tooling (x1000)**  **Total**

**Packaging Cost**

**(Component/**

**Assembly) Net** 

**Component/**

**Assembly Cost**

**Impact to OEM System** 

**ED&T/R&D**

**(x1000) Investment** 

**(X1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

assembled by OE.



### C H Cover Transaxle Electronics 02 11 #

- N0502

- 04 1 Full 1 

### 0.31 $ **11.88**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote LevelSubassemblyComponentSub-Subsystem



### Scaling

Factor

(Default =1)QTY/Subsystem 

### Notes 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**

**(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**ItemSubsystem 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

**Tooling (x1000) Total** 

**Packaging Cost**

**(Component/**

**Assembly) Net** 

**Component/**

**Assembly Cost**

**Impact to OEM System** 

**ED&T/R&D**

**(x1000) Investment** 

**(X1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: Control Module Subassembly, H Housing, Main Control Unit**  

## Part Number: **021172-N0502-01** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material

A 

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

1 1A H Housing, Main Control Unit 021103-N0502-01-4 **1** Diecast & Trim T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LS **133 3**  **3 1.1**  5.292 **$1.10 $41.48**  **$301.91 $996.30**  **$5.82 $0.94**  **$7.52 $14.28**  **5.00% 0.00%**  **0.00% 0.00%**  **5.00% $0.71**  **$14.99 $14.99**  **$5.82**

2 1B H Housing, Main Control Unit 021103-N0502-01-3 **1** Heat Treat T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast Heat Treat Operator T5-Al380, SMS **270 4**  **12 1**  5.292 **$0.012 $47.72**  **$10.17 $122.04**  **$0.06 $0.71**  **$0.45 $1.22**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.22 $1.22**  **$0.06**

3 1C H Housing, Main Control Unit 021103-N0502-01-2 **1** Machined T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast CNC Operator Transfer machining line,

Transmission cases, OEM **105 2**  **3 3**  0.000 **$1.10 $36.98**  **$81.00 $729.00**  **$0.00 $0.71**  **$6.95 $7.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$7.66 $7.66**  **$0.00**

4 1D H Housing, Main Control Unit 021103-N0502-01-1 **1** Washed T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast CNC Operator Washing Equipment MHC **277 1**  **1 1**  0.000 **$1.10 $36.98**  **$77.95 $77.95**  **$0.00 $0.13**  **$0.28 $0.42**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.42 $0.42**  **$0.00**

5 1E H Housing, Main Control Unit 021103-N0502-01 **1** Insert dowel pins T1 Assembly, Mark-up Applied Aluminum-A380, Cast General Assembly Mech Assembly, LC, Base **171 1**  **1 1**  0.000 **$1.10 $38.55**  **$15.00 $15.00**  **$0.00 $0.22**  **$0.09 $0.31**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.31 $0.31**  **$0.00** 

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

5 1E H Housing, Main Control Unit 021103-N0502-01 **1** Insert dowel pins T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast General Assembly Mech Assembly, LC, Base **171 1**  **1 1**  0.000 **$1.10 $38.55**  **$15.00 $15.00**  **$0.00 $0.22**  **$0.09 $0.31**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.31 $0.31**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### B 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: Control Module Subassembly, H Housing, Main Control Unit**  

## Part Number: **021172-N0502-01** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### C 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: Control Module Subassembly, H Housing, Main Control Unit**  

## Part Number: **021172-N0502-01** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### D 

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

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 1A H Dowel Pin, Control Unit Housing 021103-N0502-01-50 **2** S **$0.00** $0.05 **$0.00 $0.10**  **$0.10**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

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

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$5.98**

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

**Mark-up $24.70** 

**T1 or OEM Total Manufacturing Cost: $5.98**  **$2.71 $15.29**  **$23.98 $0.71**  **$0.00 $0.00**  **$0.00 $0.71**  **$24.70** 

### "Alpha

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

Supplier for Subassembly.

**3 1** 



### Notes: **T1 or OEM Total Manufacturing Cost: $5.98**  **$2.71 $15.29**  **$23.98 $0.71**  **$0.00 $0.00**  **$0.00 $0.71**  **$24.70**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

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

----- ----- ----- **$0.12 $1.61**  **$1.48 $0.62**  **$3.83**

**Base Cost Impact to Vehicle: $5.98**  **$2.71 $15.29**  **$23.98 $0.84**  **$1.61 $1.48**  **$0.62 $4.54**  **$28.53 $0**  **$0**

**Packaging Cost: $0.09** 

**Net Cost Impact to Vehicle: $28.61**  

### Notes:

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



### Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: Control Module Subassembly, H Housing, Main Control Unit**  

## Part Number: **021172-N0502-01** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.088 $175,560**  **0.00% 2,250,000**  **60 5.00%**  $440 **399** 144 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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

### PACKAGING CALCULATIONS:

Packaging Type: Option #1

Part Size: 500 x 200 x 70

Parts/Layer: 6 x 2

Number of Layers: 12 Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0



### Packaging Cost Total: **$0.088** 

### Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Housing, Main Control Unit 021103-N0502-01-4

1B H Housing, Main Control Unit 021103-N0502-01-3

1C H Housing, Main Control Unit 021103-N0502-01-2

1D H Housing, Main Control Unit 021103-N0502-01-1

1E H Housing, Main Control Unit 021103-N0502-01



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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

**$0.94 $7.52**  **$14.28 $0.71**  **$0.00 $0.00**  **$0.00 $0.71**  Single Cavity Diecast, operator load/load trim press and pack **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 81.5 1 1 81.5 **1.1 3.0** 

**$0.71 $0.45**  **$1.22 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Batch Heat Treat Process, operator load/unload **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 169 27,000 **1.0 12.0** 

**$0.71 $6.95**  **$7.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  3 CNC machining lines, three machines per module, 2 operators (9 machines total), automated

load/unload. **5.5 2**  **10 110**  **47 5170**  **87 41.36**  **85% 102**  **35.16** 309.0 1 1 103.0 **3.0 3.0** 

**$0.13 $0.28**  **$0.42 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Linear conveyor washing line, operator load unload **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13.0 1 1 13.0 **1.0 1.0** 

**$0.22 $0.09**  **$0.31 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 21.0 1 1 21.0 **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

1E H Housing, Main Control Unit 021103-N0502-01



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.22 $0.09**  **$0.31 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Operator manual load part to holding fixture, load two dowel pins, auto press home. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 21.0 1 1 21.0 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 7 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

1A H Dowel Pin, Control Unit Housing 021103-N0502-01-50 

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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.10**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$2.71 $15.29**  **$23.98 $0.71**  **$0.00 $0.00**  **$0.00 $0.71** 

**$24.70 2** 



### Notes:

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 8 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 9 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Housing, Main Control Unit 021103-N0502-01-4

1B H Housing, Main Control Unit 021103-N0502-01-3

1C H Housing, Main Control Unit 021103-N0502-01-2

1D H Housing, Main Control Unit 021103-N0502-01-1

1E H Housing, Main Control Unit 021103-N0502-01



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**133 27.17**  3.00

**270 13.31**  4.00

**105 34.33**  2.00

**277 13.00**  1.00

**171 21.00**  1.00 1E H Housing, Main Control Unit 021103-N0502-01



## Purchase Part - High Impact Item (Full Cost Mapping) **171 21.00**  1.00

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

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### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 10 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

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-

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-

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-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 11 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

1A H Dowel Pin, Control Unit Housing 021103-N0502-01-50**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 12 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Housing Electronics Subassembly (Casting & Diversion Plate Sub)**  

## Part Number: **021172-N0502-02** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material

A 

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

1 1A H Housing Electronics Assembly 021172-N0502-02 **1** Install H-Plate Coolant Passage T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base **240 1**  **1 2**  0.000 **$0.00 $38.55**  **$30.00 $60.00**  **$0.00 $0.16**  **$0.25 $0.41**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.41 $0.41**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **2** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### B 

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

1 1A H Housing Electronics 021172-N0502-02-100 **1** Diecast & Trim T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LS **133 3**  **3 1.1**  13.918 **$1.10 $41.48**  **$301.91 $996.30**  **$15.31 $0.94**  **$7.52 $23.77**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$23.77 $23.77**  **$15.31**

2 1B H Housing Electronics 021172-N0502-02-99 **1** Heat Treat T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast Heat Treat Operator T5-Al380, SMS **115 4**  **12 1**  13.918 **$0.012 $47.72**  **$10.17 $122.04**  **$0.17 $1.66**  **$1.06 $2.88**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$2.88 $2.88**  **$0.17**

3 1C H Housing Electronics 021172-N0502-02-98 **1** Machined T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast CNC Operator Transfer machining line,

Transmission cases, OEM **120 3**  **8 3**  0.000 **$1.10 $36.98**  **$81.00 $1,944.00**  **$0.00 $0.93**  **$16.25 $17.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$17.17 $17.17**  **$0.00**

4 1D H Housing Electronics 021172-N0502-02-97 **1** Washed T1 Assembly, Mark-up Applied

@ Bottom. Aluminum-A380, Cast CNC Operator Washing Equipment MHC **240 1**  **1 1**  0.000 **$1.10 $36.98**  **$77.95 $77.95**  **$0.00 $0.15**  **$0.32 $0.48**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.48 $0.48**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 2A H Plate, Coolant Passage 021172-N0502-02-95 **1** Prog. Die, Pre-form Blank T2/T3 Stamp/Form, MSMC LC-GSteel-1000S, Coil Cut/Punch/Forming OperatorOEM Stamp/Form, SS **288 0.25**  **1 1**  1.236 **$0.48 $135.07**  **$42.91 $42.91**  **$0.59 $0.12**  **$0.15 $0.86**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.12**  **$0.98 $0.98**  **$0.59**

7 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Housing Electronics Subassembly (Casting & Diversion Plate Sub)**  

## Part Number: **021172-N0502-02** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

9 **0 #####**  **0 1**  **1** 0.025 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.204 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.188 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### C 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Housing Electronics Subassembly (Casting & Diversion Plate Sub)**  

## Part Number: **021172-N0502-02** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### D 

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

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

2 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

3 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

4 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

5 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

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

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is 5 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

6 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

7 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

8 **0** 0 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$16.07** 

### T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

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

**Mark-up $45.69** 

**T1 or OEM Total Manufacturing Cost: $16.07**  **$3.96 $25.55**  **$45.57 $0.00**  **$0.06 $0.05**  **$0.01 $0.12**  **$45.69**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

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

----- ----- ----- **$0.23 $2.97**  **$2.74 $1.14**  **$7.08**

**Base Cost Impact to Vehicle: $16.07**  **$3.96 $25.55**  **$45.57 $0.23**  **$3.03 $2.79**  **$1.15 $7.20**  **$52.77 $0**  **$0**

**Packaging Cost: $0.30** 

**Net Cost Impact to Vehicle: $53.08**  **3 1** 



### Notes:

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



### Reference Packaging Database for Additional Information



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Housing Electronics Subassembly (Casting & Diversion Plate Sub)**  

## Part Number: **021172-N0502-02** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.303 $606,480**  **0.00% 2,250,000**  **60 5.00%**  $380 **1596** 36 **6 57447** 

**Packaging**

**Cost per Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Other #1** 

**Pads Other #2** 

**Packaging Other #2** 

**Pads Other #3** 

**Packaging, Other #3** 

**Pads** 

### PACKAGING CALCULATIONS:

Packaging Type: Option #1

Part Size: 630x290X90

Parts/Layer: 4x1

Number of Layers: 9 **Reference Packaging Database for Additional Information**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) **Piece Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack**



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



### Packaging Cost Total: **$0.303** 

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Housing Electronics Assembly 021172-N0502-02



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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

**$0.16 $0.25**  **$0.41 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  3 Station orbital spin workcell, S#1 Manual load casting and plate, unload staked part S#2 Automated

orbital spin station A, S#3 Automated orbital spin station B. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 25 3 1 15 **2.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **2.0 1.0** 

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

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



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

1A H Housing Electronics 021172-N0502-02-100 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.94 $7.52**  **$23.77 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Single Cavity Diecast, operator load/load trim press and pack **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 81.5 1 1 81.5 **1.1 3.0** 

1B H Housing Electronics 021172-N0502-02-99

1C H Housing Electronics 021172-N0502-02-98

1D H Housing Electronics 021172-N0502-02-97

2A H Plate, Coolant Passage 021172-N0502-02-95 **$1.66 $1.06**  **$2.88 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Batch Heat Treat Process, operator load/unload **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 72 27,000 **1.0 12.0** 

**$0.93 $16.25**  **$17.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  8 CNC machining lines, three machines per module, 3 operators (24 machines total). Automated

load/unload. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 722.0 1 1 240.7 **3.0 8.0** 

**$0.15 $0.32**  **$0.48 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Linear conveyor washing line, operator load unload **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 15.0 1 1 15.0 **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.12 $0.15**  **$0.86 $0.00**  **$0.06 $0.05**  **$0.01 $0.12**  Progressive Die, Preform Blank **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12.5 1 1 12.5 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0! 1.1**  **1.0**

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 7 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$3.96 $25.55**  **$45.57 $0.00**  **$0.06 $0.05**  **$0.01 $0.12** 

**2**

**$45.69**



### Notes:

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 8 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 9 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Housing Electronics Assembly 021172-N0502-02



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**240 15.00**  1.00

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



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

1A H Housing Electronics 021172-N0502-02-100 **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**133 27.17**  3.00

1B H Housing Electronics 021172-N0502-02-99

1C H Housing Electronics 021172-N0502-02-98

1D H Housing Electronics 021172-N0502-02-97

2A H Plate, Coolant Passage 021172-N0502-02-95 **115 31.25**  4.00

**120 30.08**  3.00

**240 15.00**  1.00

**#DIV/0! #DIV/0!** 

-

**288 12.50**  0.25

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 10 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 11 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 12 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Transmission Assembly**



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

## Annual Component Volume: Shipping Method:

**Component Description: Components PIA to Subassembly of H Housing, (Assembled by OE)**  

## Part Number: **021172-N0502-03** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material

A 

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

1 1A H Housing Electronics Assembly 021172-N0502-03-20 **0** Install Coolant Fittings OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, OEM,

LMC **138 4**  **1 9**  0.000 **$0.00 $97.48**  **$25.00 $225.00**  **$0.00 $2.82**  **$1.63 $4.44**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$4.44 $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

Relocated OE Assembly

Operations To Final Assembly

Line

- Zero Out QTY **Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### B 

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

1 **0 #####**  **0 1**  **1** 13.918 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 13.918 **$0.012 #N/A**  **#N/A #N/A**  **$0.17 #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 1.236 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.025 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.204 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.188 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Transmission Assembly**



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

## Annual Component Volume: Shipping Method:

**Component Description: Components PIA to Subassembly of H Housing, (Assembled by OE)**  

## Part Number: **021172-N0502-03** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### C 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### D 

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

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Transmission Assembly**



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

## Annual Component Volume: Shipping Method:

**Component Description: Components PIA to Subassembly of H Housing, (Assembled by OE)**  

## Part Number: **021172-N0502-03** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 1A H Coolant Outlet, Large, Trans. 021172-N0502-03-21 **2** S **$0.00** $0.60 **$0.00 $1.20**  **$1.20**

2 2A H Coolant Port, Small, Trans. 021172-N0502-03-22 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

3 3A H Stud, Housing Electronics 021172-N0502-03-23 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

4 4A H O-ring, Plug, Housing Electronics 021172-N0502-03-24 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

5 5A H Plug, Housing Electronics 021172-N0502-03-25 **1** S **$0.00** $0.04 **$0.00 $0.04**  **$0.04**

6 6A H O-ring, Vent, Housign Electronics 021172-N0502-03-26 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

7 7A H Vent, Housing Electronics 021172-N0502-03-27 **1** S **$0.00** $0.25 **$0.00 $0.25**  **$0.25**

8 8A H Temp Sensor, Housing Electronics 021172-N0502-03-28 **1** S **$0.00** $2.00 **$0.00 $2.00**  **$2.00**

9 9A H Bolt, Housing, Electronics Assembly 021172-N0502-03-29 **32** S **$0.00** $0.04 **$0.00 $1.28**  **$1.28**

10 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

Weight in Kg based on total 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

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

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

11 10A Electronic Grade Silicone 021172-N0502-03-30 **0.037** Weight in Kg based on total

mounting area of MCU, GCU, &

Cap S **$0.00** $35.00 **$0.00 $1.31**  **$1.31**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$6.18**

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

**Mark-up $6.18** 

**T1 or OEM Total Manufacturing Cost: $6.18**  **$0.00 $0.00**  **$6.18 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$6.18**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00% **3 1** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 

----- ----- ----- ----- 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**  **$0.00**

**Base Cost Impact to Vehicle: $6.18**  **$0.00 $0.00**  **$6.18 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$6.18 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $6.18**  **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Transmission Assembly**



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

## Annual Component Volume: Shipping Method:

**Component Description: Components PIA to Subassembly of H Housing, (Assembled by OE)**  

## Part Number: **021172-N0502-03** 

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



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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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

### PACKAGING CALCULATIONS:

Packaging Type: Option #1

Part Size: 630x290X90

Parts/Layer: 4x1

Number of Layers: 9 Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0



### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Housing Electronics Assembly 021172-N0502-03-20



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

Relocated OE Assembly

Operations To Final Assembly

Line

- Zero Out QTY 

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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated assembly line, S#1 Operator load pallet with casting, manual press-in vent plug, S#2 manual

load spindles with coolant fittings and temp sensor, auto rundown, S#3 Auto load and press coolant fitting,

S#4 manual install and rundown wire harness stud and oil plug. S#5 auto apply electronics silicone, S#6

auto place GCU and MCU, S#7 auto rundown 16 places S#8 auto place large cap and rundown, S#9 off

load to buffer (one operator feeding line for MCU, GCU and Large Cap) **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** 271 9 1 26 **9.0 1.0** 

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

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

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

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

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **0 #DIV/0!**  **85% 0**  **#DIV/0! 1.0**  **1.0** 

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.1 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 7 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

1A H Coolant Outlet, Large, Trans. 021172-N0502-03-21

2A H Coolant Port, Small, Trans. 021172-N0502-03-22

3A H Stud, Housing Electronics 021172-N0502-03-23

4A H O-ring, Plug, Housing Electronics 021172-N0502-03-24

5A H Plug, Housing Electronics 021172-N0502-03-25

6A H O-ring, Vent, Housign Electronics 021172-N0502-03-26

7A H Vent, Housing Electronics 021172-N0502-03-27

8A H Temp Sensor, Housing Electronics 021172-N0502-03-28

9A H Bolt, Housing, Electronics Assembly 021172-N0502-03-29 

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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$1.20**

**$0.05**

**$0.03**

**$0.01**

**$0.04**

**$0.02**

**$0.25**

**$2.00**

**$1.28**

**$0.00**

10A Electronic Grade Silicone 021172-N0502-03-30 **$1.31**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.00 $0.00**  **$6.18 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$6.18 2** 



### Notes:

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 8 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 9 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Housing Electronics Assembly 021172-N0502-03-20



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

Relocated OE Assembly

Operations To Final Assembly

Line

- Zero Out QTY**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**138 26.00**  4.00

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**#DIV/0! #DIV/0!** 



## Purchase Part - High Impact Item (Full Cost Mapping) **#DIV/0! #DIV/0!** 

-

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-

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-

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-

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-

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-

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-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 10 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

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-

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-

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-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

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-

**#DIV/0! #DIV/0!** 

-



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

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

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-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 11 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

1A H Coolant Outlet, Large, Trans. 021172-N0502-03-21

2A H Coolant Port, Small, Trans. 021172-N0502-03-22

3A H Stud, Housing Electronics 021172-N0502-03-23

4A H O-ring, Plug, Housing Electronics 021172-N0502-03-24

5A H Plug, Housing Electronics 021172-N0502-03-25

6A H O-ring, Vent, Housign Electronics 021172-N0502-03-26

7A H Vent, Housing Electronics 021172-N0502-03-27

8A H Temp Sensor, Housing Electronics 021172-N0502-03-28

9A H Bolt, Housing, Electronics Assembly 021172-N0502-03-29**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

10A Electronic Grade Silicone 021172-N0502-03-30



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 12 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Cover Transaxle Electronics**  

## Part Number: **021172-N0502-04** 

## We ekly Component Volume: Packaging Specification:

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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material

A 

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

1 1A H Cover Transaxle Electronics 021172-N0502-4 **1** Final Case Assembly T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base **240 2**  **1 2**  0.000 **$0.00 $38.55**  **$30.00 $60.00**  **$0.00 $0.32**  **$0.25 $0.57**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.57 $0.57**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### B 

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

1 1A H Cover Transaxle Electronic - Stamped 021172-N0502-04-10 **1** Progressive Stamp T1 Assembly, Mark-up Applied

@ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS **190 1**  **1 6**  6.407 **$0.48 $42.73**  **$60.65 $363.90**  **$3.08 $0.22**  **$1.91 $5.21**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$5.21 $5.21**  **$3.08**

2 1B H Cover Transaxle Electronic - Washed 021172-N0502-04-10 **1** Converyor Wash T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable Cut/Punch/Forming Operator Washing Equipment MHC **277 1**  **1 1**  0.000 **$0.00 $42.73**  **$77.95 $77.95**  **$0.00 $0.15**  **$0.28 $0.44**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.44 $0.44**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Cover Transaxle Electronics**  

## Part Number: **021172-N0502-04** 

## We ekly Component Volume: Packaging Specification:

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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### C 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Cover Transaxle Electronics**  

## Part Number: **021172-N0502-04** 

## We ekly Component Volume: Packaging Specification:

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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### D 

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

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 1A H Tab Electronics Stamping - Cover 021172-N0502-04-20 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

2 2A H Clip Saftey Switch 021172-N0502-04-21 **1** S **$0.00** $0.14 **$0.00 $0.14**  **$0.14**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 3 Parts assembled to the Cover Assembly,

assembled by the OE. Assembly $ covered in Trans

Assembly - 020000- **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 3A H Label, Cover Electronics, HV 021172-N0502-04-22 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

6 3B H Label, Cover Electronics, Info 021172-N0502-04-23 **1** S **$0.00** $0.15 **$0.00 $0.15**  **$0.15**

7 3C H Gasket Trans Elec Cover 021172-N0502-04-24 **1** S **$0.00** $3.25 **$0.00 $3.25**  **$3.25** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

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

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 7 3C H Gasket Trans Elec Cover 021172-N0502-04-24 **1** S **$0.00** $3.25 **$0.00 $3.25**  **$3.25**

8 3D H Bolt Trans Axle Cover 021172-N0502-04-25 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

9 3E H Stud, Cover Electonics 021172-N0502-04-26 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

10 3F **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$6.88**

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

**Mark-up $10.02**  

### "Alpha

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

Supplier for Subassembly.

**1**

**T1 or OEM Total Manufacturing Cost: $6.88**  **$0.70 $2.44**  **$10.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$10.02**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

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

----- ----- ----- **$0.05 $0.65**  **$0.60 $0.25**  **$1.55**

**Base Cost Impact to Vehicle: $6.88**  **$0.70 $2.44**  **$10.02 $0.05**  **$0.65 $0.60**  **$0.25 $1.55**  **$11.57 $0**  **$0**

**Packaging Cost: $0.31** 

**Net Cost Impact to Vehicle: $11.88**  **3** 

### Notes:

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



### Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 12 

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

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

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



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

## Annual Component Volume: Shipping Method:

**Component Description: H Cover Transaxle Electronics**  

## Part Number: **021172-N0502-04** 

## We ekly Component Volume: Packaging Specification:

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

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

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

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.306 $612,800**  **0.00% 2,250,000**  **60 5.00%**  $320 **1915** 30 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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

### PACKAGING CALCULATIONS:

Packaging Type: Option #1

Part Size: 730x230X130

Parts/Layer: 6

Number of Layers: 5 Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0



### Packaging Cost Total: **$0.306** 

### Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Cover Transaxle Electronics 021172-N0502-4



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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

**$0.32 $0.25**  **$0.57 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Semi Automated 2 cell workstation, S#1 load cover and terminal, spot weld, S#2 install clip, safety switch

and pack. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 2 1 15 **2.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



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

1A H Cover Transaxle Electronic - Stamped 021172-N0502-04-10 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.22 $1.91**  **$5.21 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  4 Station tandem press line, automated part handling (X1.5 for Automation) **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19 4 1 19 **6.0 1.0** 

1B H Cover Transaxle Electronic - Washed 021172-N0502-04-10 **$0.15 $0.28**  **$0.44 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Conveyor Wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 7 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

1A H Tab Electronics Stamping - Cover 021172-N0502-04-20

2A H Clip Saftey Switch 021172-N0502-04-21

3 Parts assembled to the Cover Assembly,

assembled by the OE. Assembly $ covered in Trans

Assembly - 020000-

3A H Label, Cover Electronics, HV 021172-N0502-04-22

3B H Label, Cover Electronics, Info 021172-N0502-04-23

3C H Gasket Trans Elec Cover 021172-N0502-04-24 

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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.06**

**$0.14**

**$0.00**

**$0.00**

**$0.10**

**$0.15**

**$3.25** 3C H Gasket Trans Elec Cover 021172-N0502-04-24

3D H Bolt Trans Axle Cover 021172-N0502-04-25

3E H Stud, Cover Electonics 021172-N0502-04-26

3F **$3.25**

**$0.05**

**$0.05**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.70 $2.44**  **$10.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$10.02 2** 



### Notes:

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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 8 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item

**Scrap SG&A**  **Profit ED&T** 

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

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 9 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A H Cover Transaxle Electronics 021172-N0502-4



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**240 15.00**  2.00

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



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

1A H Cover Transaxle Electronic - Stamped 021172-N0502-04-10 **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**190 18.90**  1.00

1B H Cover Transaxle Electronic - Washed 021172-N0502-04-10 **277 13.00**  1.00

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 10 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

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**#DIV/0! #DIV/0!** 

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### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 11 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

1A H Tab Electronics Stamping - Cover 021172-N0502-04-20

2A H Clip Saftey Switch 021172-N0502-04-21

3 Parts assembled to the Cover Assembly,

assembled by the OE. Assembly $ covered in Trans

Assembly - 020000-

3A H Label, Cover Electronics, HV 021172-N0502-04-22

3B H Label, Cover Electronics, Info 021172-N0502-04-23

3C H Gasket Trans Elec Cover 021172-N0502-04-24**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

3C H Gasket Trans Elec Cover 021172-N0502-04-24

3D H Bolt Trans Axle Cover 021172-N0502-04-25

3E H Stud, Cover Electonics 021172-N0502-04-26

3F



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 12 of 12 

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

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411