### 5

- A

- i APPENDIX 5

- A. DRAFT ENGINEERING AN ALYSIS DATA REQUEST SHEETS

TABLE OF CO NTENTS

5

- A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR

RESIDENTIAL CLOTHES WASHERS

................................ ................................ .... 1

LIST OF TABLES

Table 5

- A.1.1 Residential Clothes Washer Shipments

................................ ................................ 2

Table 5

- A.1.2 Shipment

- Weighted Average Efficiency Data

................................ ....................... 2

Table 5

- A.1.3 Market Share Efficiency D ata: Top

- Loading

– Compact and Standard, and

Front

- Loading

................................ ................................ ................................ 3

Table 5

- A.1.4 Manufacturer Cost Data: Top

- Loading

– Compact and Standard

........................... 4

Table 5

- A.1

. 5 Manufacturer Cost Data: Front

- Loading

................................ ............................... 5

### 5

- A

- 1 5

- A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR

RESIDENTIAL CLOTHES WASHERS

DOE seeks average incremental production cost to take basic models in the categories shown

from the curr ent DOE minimum efficiency level (or proposed baseline level) to the specified

efficiency level. For those product classes where more than one basic model may exist, please

indicate the minimum and maximum incremental costs that would be incurred across th e array of

basic models.

The data sheets are divided by product and contain tables requesting shipment and manufacturer

cost data.

The shipment

- weighted energy use data of Table A2 should be based on the DOE clothes washer

test procedure (10 CFR 430, sub part B, appendix J, J1).

Shipments

For residential clothes washers, the AHAM 2005 Fact Book offers historical shipments data, but

the information is not disaggregated by product class. As shown in the “shipment request” tables

below, DOE hopes to collect both shipments data and shipment

- weighted average efficiency data

dating back to 1993. In addition, DOE hopes to collect market share efficiency ( i.e. , data on the

distribution of product shipments by efficiency) for each product class.

Manufacturer Cost s

Incremental cost data (in U.S. dollars) include the materials, labor, and overhead needed to take

basic models from the current minimum DOE baseline efficiency standard to each higher

efficiency level. The depreciation of the conversion cap ital expenditures is an important

component of the overhead for DOE to understand. Therefore, DOE is requesting information

about conversion capital expenditures by efficiency level.

### 5

- A

- 2 Table 5

- A.1

. 1 Residential Clothes Washer Shipments

Year Shipments, Domestic + Imports

(Thousands of Units)

Top

- Loading Front

Loading Suds

- Saving Compact Standard Semi

automatic

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008



### Table 5

- A.1

. 2 Shipment

- Weighted Average Efficiency Data

Year Shipment

- Weighted Average Efficiency

Top

- Loading Front

- Loading Suds

- Saving Compact Standard Semiautomatic

(MEF or EF) (WF) (MEF or EF) (WF) (MEF or EF) (WF) (MEF or EF) (WF) (MEF or EF) (WF)

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

### 5

- A

- 3 Table 5

- A.1

. 3 Market Share Efficiency Data: Top

- Loading

– Compact and Standard, and Front

Loading

Top

- Loading

- Compact Top

- Loading

- Standard Front

- Loading

Efficiency

Bins Market Share

(Percent)* Efficiency

Bins Market Share

(Percent)* Efficiency

Bins Market Share

(Percent)*

(MEF) (WF) 2006 2007 2008 (MEF) (WF) 2006 2007 2008 (MEF) (WF) 2006 2007 2008

0.6 5 18.40 1.26 9.50 1.72 8.00

0.78 13.90 1.40 9.50 1.80 7.50

1.72 8.00 2.00 6.00

1.80 7.50 2.20 4.50

2.00 6.00 2.40 4.20

2.25 4.45 2.89 3.36

* Total market share percentages for each year should equal 100%. DOE believes that there are no top

- loading semi

automatic or suds

- saving residential clothes washers currently on the market in the United States.

### 5

- A

- 4 Table 5

- A.1

. 4 Manufacturer Cost Data: Top

- Loading

– Compact and Standard

Product Class  Top

- Loading

– Compact Top

- Loading

– Standard

Efficiency Level 1 1 2 3 4 5

MEF 0.78 1.40 1.72 1.80 2.00 2.25

WF 13.90 9.50 8.00 7.50 6.00 4.45

Average Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX

Tooling/ Equipment CAPX

One

- Time Product Conversion Expenses ($, Millions)

R&D

Marketing

# Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead.

* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the feder al standard for

residential clothes washers and is equal to an MEF of 1.26 and WF of 9.50 for Top

- Loading

– Standard and an MEF of 0.65 for Top

Loading

- Compact. The baseline WF of 18.40 for Top

- Loading

– Compact was selected based on a survey of clothes washers listed in the

NRCan product database.

Other Information:

1. What depreciation method would your company use to depreciate the conversion capital expenditures?

_______________________________________________.

Direct material

– Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indi rect material

costs which are attributed to supplies that may be used in the production process but are not assigned to final products ( e.g ., lubricating oil for production

machinery).

Direct labor

– The earnings of workers who assemble parts into a finished good for operate machin es in the production process. Direct labor includes the

fringe benefits of direct laborers such as group health care, as well as overtime pay. Direct labor does not include indirect labor which is defined as the

earnings of employees who do not work direct ly in assembling a product, such as supervisors, janitors, stockroom personnel, inspectors, and forklift

operators.

Overhead

– Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set

- up costs, indirect material, exp endable tools,

maintenance, property taxes, insurance on assets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A);

R&D; interest; or profit (accounted for by DOE separately).

Full Production Cost = Dire ct Material + Direct Labor + Overhead (factory) + Depreciation

Full Cost of Product = Full Production Cost + Non

- production Costs (SG&A, R&D, interest, and profit)

### 5

- A

- 5 Table 5

- A.1

. 5 Manufacturer Cost Da ta: Front

- Loading

Product Class  Front

- Loading

Efficiency Level 1 2 3 4 5

MEF 1.80 2.00 2.20 2.40 2.89

WF 7.50 6.00 4.50 4.20 3.36

Average Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX

Tooling/ Equipment CAPX

One

- Time Product Conversion Expenses ($, Millions)

R&D

Marketing

# Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead.

* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit for the front

loading product class complies with the current ENERGY STAR level for residential clothes washers and is equal to an

MEF of 1.72 and WF of 8.00.

Other Information:

1. What depreciation method would your company use to depreciate the conversion capital expenditures?

_______________________________________________.

Direct material

– Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not

include indirect material costs which are attributed to supplies that may be used in the production process but are not assig ned to final

pr oducts ( e.g ., lubricating oil for production machinery).

Direct labor

– The earnings of workers who assemble parts into a finished good for operate machines in the production process.

Direct labor includes the fringe benefits of direct laborers such as gro up health care, as well as overtime pay. Direct labor does not

include indirect labor which is defined as the earnings of employees who do not work directly in assembling a product, such a s

supervisors, janitors, stockroom personnel, inspectors, and forkli ft operators.

Overhead

– Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set

- up costs, indirect

material, expendable tools, maintenance, property taxes, insurance on assets, and utility costs. Factory overhead d oes not include

selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accounted for by DOE

separately).

Full Production Cost = Direct Material + Direct Labor + Overhead (factory) + Depreciation

Full Cost of Product = Full Production Cost + Non

- production Costs (SG&A, R&D, interest, and profit)