### Page:1 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

26.57 $

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



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00 Vehicle Installation of Power Brake Subsystem (for Hydraulic)**  **0.16 $**  **1.71**

**$ 0.26** 

**$ 2.13** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.13** 

**$**



### 2 **01 Vacuum Booster**  **21.15 $**  **13.30**

**$ 18.89** 

**$ 53.33** 

**$ 0.33** 

**$ 4.75** 

**$ 4.09** 

**$ 1.39** 

**$ 10.57** 

**$**

**-**

**$ 63.90** 

**$ Based on % Change in ETW applied against** 

**material portion of cost Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem



### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Scaling Parameter(s) Description**  **Notes** 

# 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)

3 **02 Vacuum Pump and Motor**  **22.15 $**  **16.75**

**$ 23.92** 

**$ 62.81** 

**$ 0.36** 

**$ 4.98** 

**$ 4.38** 

**$ 1.59** 

**$ 11.32** 

**$ 0.10** 

**$ 74.23** 

**$ Based on % Change in ETW applied against** 

**material portion of cost**



### 4 **03 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 5 **04 Hydraulic Booster** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 6 **07 Vacuum Reservoir and Distribution Components** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **60 Wiring Harness Connections**  **3.03 $**  **2.12**

**$ 0.91** 

**$ 6.06** 

**$ 0.03** 

**$ 0.39** 

**$ 0.36** 

**$ 0.15** 

**$ 0.94** 

**$ 0.08** 

**$ 7.08** 

**$ No Change** 



### 9 **70 Pipes, Hoses, Ducting**  **1.63 $**  **0.36**

**$ 0.30** 

**$ 2.29** 

**$ 0.01** 

**$ 0.20** 

**$ 0.17** 

**$ 0.06** 

**$ 0.44** 

**$ 0.04** 

**$ 2.77** 

**$ Negligible Difference** 



### 10 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 48.11 **$ 34.24** 

**$ 44.27** 

**$ 126.63** 

**$ 0.74** 

**$ 10.32** 

**$ 9.01** 

**$ 3.19** 

**$ 23.26** 

**$ 0.22** 

**$ 150.11** 

**$**

**-**

**$** 

### 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:2 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

26.57 $

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem



### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Scaling Parameter(s) Description**  **Notes** 

# 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 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

26.57 $

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem



### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Scaling Parameter(s) Description**  **Notes** 

# 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)

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



# 05 **Cy linder Blocks** 

A1 **01**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

B1 **02**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

C1 **03**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

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



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

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem 

### Net **Component/ Assembly**  **Cost Impact to**

**OEM** Markup 

# BASE

**TECHNO**

**LOGY**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**



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

E1 **65**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

26.57 $

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem



### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Scaling Parameter(s) Description**  **Notes** 

# 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)

F1 **66**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

G1 **67**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

H1 **70**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

I1 **75**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

J1 **80**

**- $** 

**- $** 

**- $** 

- $

-

$

-

$ **$**

- $

-

$

-

$

-

$ **$**

- $ **$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

K1 **85**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

L1 **90**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

M1 **99**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

N1 **00**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**SU**

**BS**

**YS** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

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



# 05 **Cy linder Blocks** 

A1 **01** 0.16 $ 1.71

$ 0.26

$ **2.13**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **2.13**

**$ Total**  **Manufacturing**

**Cost (Component/**  **Assembly)** Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# TECHNO

**LOGY**

**PACKAG INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE** ItemSubsystemSub-Subsystem 

### Manufacturing



### B1 **02** 21.15 $ 13.30

$ 18.89

$ **53.33**

**$** 0.33

$ 4.75

$ 4.09

$ 1.39

$ **10.57**

**$**

-

$ **63.90**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

26.57 $

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem



### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Scaling Parameter(s) Description**  **Notes** 

# 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)

C1 **03** 22.15 $ 16.75

$ 23.92

$ **62.81**

**$** 0.36

$ 4.98

$ 4.38

$ 1.59

$ **11.32**

**$** 0.10

$ **74.23**

**$**



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



### E1 **65**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### F1 **66**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### G1 **67**

**- $** 

**- $** 

**- $** 

- $

-

$

-

$ **$**

- $

-

$

-

$

-

$ **$**

- $ **$**



### H1 **70** 3.03 $ 2.12

$ 0.91

$ **6.06**

**$** 0.03

$ 0.39

$ 0.36

$ 0.15

$ **0.94**

**$** 0.08

$ **7.08**

**$**



### I1 **75** 1.63 $ 0.36

$ 0.30

$ **2.29**

**$** 0.01

$ 0.20

$ 0.17

$ 0.06

$ **0.44**

**$** 0.04

$ **2.77**

**$**



### J1 **80**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### K1 **85**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### L1 **90**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

M1 **99**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### N1 **00**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**



### SU

**BS**

**YS** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00**

2 **01**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Scaling Factor**

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value** Material Labor Burden End Item Scrap SG&A Profit

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**0.78 58.52** 

**$ 0.90**  **61.33 $**  **0.98 63.44**  **$ 1.00**  **63.82 $**  **0.94 62.50**  **$ 1.13**  **67.21 $**  **6.30 $**  **6.24**

**$ 4.87** 

**$ 17.40** 

**$ 0.09** 

**$ 1.24** 

**$ 1.12** 

**$** 

# 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)** 

**Passenger or Commercial Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup **Sub-Compact Vehicle Segment Passenger 2-4**  **(e.g. Ford Fiesta) Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)** 



### 3 **02**

4 **03**

5 **04**

6 **07**

7 **10**

8 **60**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

14 **99 0.78**  **68.66 $**  **0.90 71.57**  **$ 0.98**  **73.75 $**  **1.00 74.14**  **$ 0.94**  **72.78 $**  **1.13 77.66**  **$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**1.00 7.08** 

**$ 1.00**  **7.08 $**  **1.00 7.08**  **$ 1.00**  **7.08 $**  **1.00 7.08**  **$ 1.00**  **7.08 $** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**1.00 2.77** 

**$ 1.00**  **2.77 $**  **1.00 2.77**  **$ 1.00**  **2.77 $**  **1.00 2.77**  **$ 1.00**  **2.77 $**  **0.65 $**  **0.23**

**$ 0.21** 

**$ 1.09** 

**$ 0.01** 

**$ 0.10** 

**$ 0.09** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**137.03 $**  **142.76 $**  **147.04 $**  **147.81 $**  **145.13 $**  **154.72 $**  

### 6.95

**$ 6.47** 

**$ 5.07** 

**$ 18.49** 

**$ 0.10** 

**$ 1.34** 

**$ 1.21** 

**$**

1 2 3 4 5 6



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:7 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Scaling Factor**

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value** Material Labor Burden End Item Scrap SG&A Profit 

# 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)** 

**Passenger or Commercial Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup **Sub-Compact Vehicle Segment Passenger 2-4**  **(e.g. Ford Fiesta) Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)** 



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:8 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Scaling Factor**

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value** Material Labor Burden End Item Scrap SG&A Profit 

# 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)** 

**Passenger or Commercial Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup **Sub-Compact Vehicle Segment Passenger 2-4**  **(e.g. Ford Fiesta) Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)** 



# 05 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2ItemSubsystemSub-Subsystem 

# BASE

**TECHNO**

**LOGY**

Material Labor Burden End Item Scrap SG&A Profit

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

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



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

# BASE TECHNOLOGY PACKAGE COST INFORMATION

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup



### 2

E1 **65**

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

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:9 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

F1 **66**

2

G1 **67**

2

H1 **70**

2

I1 **75**

2

J1 **80 Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value** Material Labor Burden End Item Scrap SG&A Profit 

# 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)** 

**Passenger or Commercial Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup **Sub-Compact Vehicle Segment Passenger 2-4**  **(e.g. Ford Fiesta) Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)** 

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

**- $**  

### J1 **80**

2

K1 **85**

2

L1 **90**

2

M1 **99**

2

N1 **00**

2

**SU**

**BS**

**YS**



# 05 **Cy linder Blocks** 

A1 **01** 

# TECHNO

**LOGY**

**PACKAG**ItemSubsystemSub-Subsystem 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

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

Material Labor Burden End Item Scrap SG&A Profit

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$ Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

B1 **02** 6.30 $ 6.24

$ 4.87

$ **17.40**

**$** 0.09

$ 1.24

$ 1.12

$



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:10 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

C1 **03**

D1 **04**

E1 **65**

F1 **66**

G1 **67 Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor** 

**Relative to Base (Ford Fusion HEV)**  **Value** Material Labor Burden End Item Scrap SG&A Profit 

# 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)** 

**Passenger or Commercial Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup **Sub-Compact Vehicle Segment Passenger 2-4**  **(e.g. Ford Fiesta) Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)** 

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

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

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

**- $**  

### G1 **67**

H1 **70**

I1 **75**

J1 **80**

K1 **85**

L1 **90**

M1 **99**

N1 **00**

**SU**

**BS**

**YS** - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

0.65 $ 0.23

$ 0.21

$ **1.09**

**$** 0.01

$ 0.10

$ 0.09

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

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



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

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:11 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00**

2 **01**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

ED&T-R&D **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  Material Labor Burden End Item Scrap SG&A

**- $** 

**-**

**$**

**-**

**$**

**-**

**$ 0.16**  **$ 1.71** 

**$ 0.26** 

**$ 2.13** 

**$**

**-**

**$**

**-**

**$**

**0.44 $**  **2.89**

**$**

**-**

**$ 20.30** 

**$ 0.78** 

**$ 18.73** 

**$ 0.90** 

**$ 19.55** 

**$ 0.98** 

**$ 20.16** 

**$ 1.00** 

**$ 20.27** 

**$ 0.94** 

**$ 19.89** 

**$ 1.13** 

**$ 21.26** 

**$ 14.85** 

**$ 7.06** 

**$ 14.02** 

**$ 35.93** 

**$ 0.24** 

**$ 3.51** 

**$** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM Passenger or Commercial**  **Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)** 



### 3 **02**

4 **03**

5 **04**

6 **07**

7 **10**

8 **60**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

14 **99 -** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 22.15**  **$ 16.75** 

**$ 23.92** 

**$ 62.81** 

**$ 0.36** 

**$ 4.98** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$ 3.03**  **$ 2.12** 

**$ 0.91** 

**$ 6.06** 

**$ 0.03** 

**$ 0.39** 

**$**

**0.03 $**  **0.23**

**$ 0.02** 

**$ 1.34** 

**$ 1.00** 

**$ 1.34** 

**$ 1.00** 

**$ 1.34** 

**$ 1.00** 

**$ 1.34** 

**$ 1.00** 

**$ 1.34** 

**$ 1.00** 

**$ 1.34** 

**$ 1.00** 

**$ 1.34** 

**$ 0.98** 

**$ 0.13** 

**$ 0.09** 

**$ 1.20** 

**$ 0.01** 

**$ 0.09** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0.47 **$ 3.12** 

**$ 0.02** 

**$ 21.63** 

**$ 20.06**  **$ 20.88**  **$ 21.50**  **$ 21.61**  **$ 21.23**  **$ 22.60**  **$ 41.16** 

**$ 27.77** 

**$ 39.20** 

**$ 108.13** 

**$ 0.64** 

**$ 8.98** 

**$**

1 2 3 4 5 6



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:12 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

ED&T-R&D **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  Material Labor Burden End Item Scrap SG&A 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM Passenger or Commercial**  **Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)** 



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:13 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

ED&T-R&D **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  Material Labor Burden End Item Scrap SG&A 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM Passenger or Commercial**  **Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)** 



# 05 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2ItemSubsystemSub-Subsystem 

# BASE

**TECHNO**

**LOGY**

ED&T-R&D

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

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



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



# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**



### 2

E1 **65**

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

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:14 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

F1 **66**

2

G1 **67**

2

H1 **70**

2

I1 **75**

2

J1 **80** ED&T-R&D **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  Material Labor Burden End Item Scrap SG&A 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM Passenger or Commercial**  **Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)** 

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

**- $** 

**- $**  

### J1 **80**

2

K1 **85**

2

L1 **90**

2

M1 **99**

2

N1 **00**

2

**SU**

**BS**

**YS**



# 05 **Cy linder Blocks** 

A1 **01** 

# TECHNO

**LOGY**

**PACKAG**ItemSubsystemSub-Subsystem 

### -

$

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

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

ED&T-R&D

- $

**-**

**$**

-

$

**-**

**$** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

**Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM**



### B1 **02** 0.44

$ **2.89**

**$**

-

$ **20.30**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:15 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

C1 **03**

D1 **04**

E1 **65**

F1 **66**

G1 **67** ED&T-R&D **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  **Scaling Factor**

**Relative to Base (Ford**  **Fusion HEV) Value**  Material Labor Burden End Item Scrap SG&A 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** Markup 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM Passenger or Commercial**  **Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR) (e.g. Ford F150 6.2L V8)**  **Passenger + Midsize Towing Truck Segment**  **Passenger 5-6 Towing 4000-5000lbs**  **(10,000 lb GCWR) (e.g. Ford Explorer, 3.5L V6)**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment**  **Passenger 2-5 (e.g. Ford Focus)**  **Mid Size/Vehicle Segment Passenger 4-6**  **(e.g. Ford Fusion) Large Size Vehicle Segment**  **Passenger 6-8 (e.g. Ford Flex)** 

- $

**-**

**$**

-

$

**-**

**$**

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

- $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**

**- $** 

**- $**  

### G1 **67**

H1 **70**

I1 **75**

J1 **80**

K1 **85**

L1 **90**

M1 **99**

N1 **00**

**SU**

**BS**

**YS** - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**

0.03 $ **0.23**

**$** 0.02

$ **1.34**

**$**

- $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**



### - $

**-**

**$**

-

$

**-**

**$**

- $

**-**

**$**

-

$

**-**

**$**

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



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

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:16 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00**

2 **01**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

Profit ED&T-R&D

**- $** 

**-**

**$**

**-**

**$**

**-**

**$ 2.13** 

**$**

**2.97 $**  **0.95**

**$ 7.67** 

**$**

**-**

**$ 43.60** 

**$ Total**  **Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup **Total Markup**

**Cost (Component/**  **Assembly)**



### 3 **02**

4 **03**

5 **04**

6 **07**

7 **10**

8 **60**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

14 **99 4.38** 

**$ 1.59** 

**$ 11.32** 

**$ 0.10** 

**$ 74.23** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**0.36 $**  **0.15**

**$ 0.94** 

**$ 0.08** 

**$ 7.08** 

**$**

**0.08 $**  **0.03**

**$ 0.21** 

**$ 0.02** 

**$ 1.43** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7.80 **$ 2.72** 

**$ 20.14** 

**$ 0.20** 

**$ 128.48** 

**$**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:17 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

Profit ED&T-R&D **Total Packaging** 

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup **Total Markup**

**Cost (Component/**  **Assembly)**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:18 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

Profit ED&T-R&D **Total Packaging** 

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup **Total Markup**

**Cost (Component/**  **Assembly)**



# 05 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2ItemSubsystemSub-Subsystem 

# BASE

**TECHNO**

**LOGY**

2

E1 **65**

2

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:19 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

F1 **66**

2

G1 **67**

2

H1 **70**

2

I1 **75**

2

J1 **80** Profit ED&T-R&D **Total Packaging** 

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup **Total Markup**

**Cost (Component/**  **Assembly)**



### J1 **80**

2

K1 **85**

2

L1 **90**

2

M1 **99**

2

N1 **00**

2

**SU**

**BS**

**YS**



# 05 **Cy linder Blocks** 

A1 **01** 

# TECHNO

**LOGY**

**PACKAG**ItemSubsystemSub-Subsystem



### B1 **02**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:20 of 20 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

C1 **03**

D1 **04**

E1 **65**

F1 **66**

G1 **67** Profit ED&T-R&D **Total Packaging** 

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup **Total Markup**

**Cost (Component/**  **Assembly)**



### G1 **67**

H1 **70**

I1 **75**

J1 **80**

K1 **85**

L1 **90**

M1 **99**

N1 **00**

**SU**

**BS**

**YS**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 15 

# 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



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00 Vehicle Installation of Power Brake Subsystem (for Hydraulic)**  **0.16 $**  **1.71**

**$ 0.26** 

**$ 2.13** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.13** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 2 **01 Vacuum Booster**  **21.15 $**  **13.30**

**$ 18.89** 

**$ 53.33** 

**$ 0.33** 

**$ 4.75** 

**$ 4.09** 

**$ 1.39** 

**$ 10.57** 

**$**

**-**

**$ 63.90** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 6.30** 

**$ 6.24** 

**$ 4.87** 

**$ 17.40** 

**$**



### 3 **02 Vacuum Pump and Motor**  **22.15 $**  **16.75**

**$ 23.92** 

**$ 62.81** 

**$ 0.36** 

**$ 4.98** 

**$ 4.38** 

**$ 1.59** 

**$ 11.32** 

**$ 0.10** 

**$ 74.23** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 4 **03 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 5 **04 Hydraulic Booster** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem 

### System

**ED&T/R&D (x1000)**  **Investment (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 **07 Vacuum Reservoir and Distribution Components** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **60 Wiring Harness Connections**  **3.03 $**  **2.12**

**$ 0.91** 

**$ 6.06** 

**$ 0.03** 

**$ 0.39** 

**$ 0.36** 

**$ 0.15** 

**$ 0.94** 

**$ 0.08** 

**$ 7.08** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 9 **70 Pipes, Hoses, Ducting**  **1.63 $**  **0.36**

**$ 0.30** 

**$ 2.29** 

**$ 0.01** 

**$ 0.20** 

**$ 0.17** 

**$ 0.06** 

**$ 0.44** 

**$ 0.04** 

**$ 2.77** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.65** 

**$ 0.23** 

**$ 0.21** 

**$ 1.09** 

**$**



### 10 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 48.11 **$ 34.24** 

**$ 44.27** 

**$ 126.63** 

**$ 0.74** 

**$ 10.32** 

**$ 9.01** 

**$ 3.19** 

**$ 23.26** 

**$ 0.22** 

**$ 150.11** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 6.95

**$ 6.47** 

**$ 5.07** 

**$ 18.49** 

**$ 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:2 of 15 

# 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**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem 

### System

**ED&T/R&D (x1000)**  **Investment (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:3 of 15 

# 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**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem 

### System

**ED&T/R&D (x1000)**  **Investment (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)

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

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATION

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **Net**

**Component/ Assembly**  **Cost Impact to** Markup 

# BASE

**TECHNO**

**LOGY**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem



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



# 05 **Cy linder Blocks** 

A1 **01**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

B1 **02**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

C1 **03**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

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

- $

-

$

-

$ #REF! #REF! #REF! **#REF!**



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

**- $** 

**-**

**$**

**-**

**$** 

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

E1 **65**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

F1 **66**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

G1 **67**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

H1 **70**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

I1 **75**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

J1 **80**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

K1 **85**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

L1 **90**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$ (x1000)**  **(Component/ Assembly)**  **Assembly) (Component** 

**/ Assembly) Cost Impact to** 

**OEM (Component/**  **Assembly)**SubsystemSub-Subsystem



### L1 **90**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 15 

# 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**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem 

### System

**ED&T/R&D (x1000)**  **Investment (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)

M1 **99**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

N1 **00**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

**SU**

**BS**

**YS** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 

**-**

**$**

**-**

**$** 

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



# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total** 

# TECHNO

**LOGY**

**PACKAG INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE** SubsystemSub-Subsystem 

### Manufacturing **Total** Markup **Total Markup Total**  **Net**

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



# 05 **Cy linder Blocks** 

A1 **01** 0.16 $ 1.71

$ 0.26

$ **2.13**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **2.13**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### B1 **02** 21.15 $ 13.30

$ 18.89

$ **53.33**

**$** 0.33

$ 4.75

$ 4.09

$ 1.39

$ **10.57**

**$**

-

$ **63.90**

**$**

-

$

-

$

-

$ 6.30

$ 6.24

$ 4.87

$ **17.40**

**$**



### C1 **03** 22.15 $ 16.75

$ 23.92

$ **62.81**

**$** 0.36

$ 4.98

$ 4.38

$ 1.59

$ **11.32**

**$** 0.10

$ **74.23**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



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

- $

-

$

-

$ #REF! #REF! #REF! **#REF!**



### E1 **65**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### F1 **66**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### G1 **67**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### H1 **70** 3.03 $ 2.12

$ 0.91

$ **6.06**

**$** 0.03

$ 0.39

$ 0.36

$ 0.15

$ **0.94**

**$** 0.08

$ **7.08**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### I1 **75** 1.63 $ 0.36

$ 0.30

$ **2.29**

**$** 0.01

$ 0.20

$ 0.17

$ 0.06

$ **0.44**

**$** 0.04

$ **2.77**

**$**

-

$

-

$

-

$ 0.65

$ 0.23

$ 0.21

$ **1.09**

**$**



### J1 **80**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### K1 **85**

**- $** 

**- $** 

**- $** 

**- $**  **System**

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000) Manufacturing** 

**Cost (Component/**  **Assembly)**ItemSubsystemSub-Subsystem 

### Manufacturing

**Cost (Component/**  **Assembly) Total Markup** 

**Cost (Component/**  **Assembly) Packaging** 

**Cost (Component**  **/ Assembly) Component/** 

**Assembly Cost Impact to** 

**OEM**



### K1 **85**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 15 

# 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**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# 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)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly)**ItemSubsystem 

### System

**ED&T/R&D (x1000)**  **Investment (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)

L1 **90**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

M1 **99**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### N1 **00**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$ #REF! #REF! #REF! **#REF!**



### SU

**BS**

**YS** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 

**-**

**$**

**-**

**$** 

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

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00**

2 **01**

3 **02**

4 **03**

5 **04** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### End Item

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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.16** 

**$ 1.71** 

**$ 0.26** 

**$ 2.13** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.13** 

**$**

**-**

**$**

**-**

**$**

**0.09 $**  **1.24**

**$ 1.12** 

**$ 0.44** 

**$ 2.89** 

**$**

**-**

**$ 20.30** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 14.85** 

**$ 7.06** 

**$ 14.02** 

**$ 35.93** 

**$ 0.24** 

**$ 3.51** 

**$ 2.97** 

**$ 0.95** 

**$ 7.67** 

**$**

**-**

**$ 43.60** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 22.15** 

**$ 16.75** 

**$ 23.92** 

**$ 62.81** 

**$ 0.36** 

**$ 4.98** 

**$ 4.38** 

**$ 1.59** 

**$ 11.32** 

**$ 0.10** 

**$ 74.23** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ System** 

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) System** 

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# 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**



### 6 **07**

7 **10**

8 **60**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

14 **99 -** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 3.03** 

**$ 2.12** 

**$ 0.91** 

**$ 6.06** 

**$ 0.03** 

**$ 0.39** 

**$ 0.36** 

**$ 0.15** 

**$ 0.94** 

**$ 0.08** 

**$ 7.08** 

**$**

**-**

**$**

**-**

**$**

**0.01 $**  **0.10**

**$ 0.09** 

**$ 0.03** 

**$ 0.23** 

**$ 0.02** 

**$ 1.34** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.98** 

**$ 0.13** 

**$ 0.09** 

**$ 1.20** 

**$ 0.01** 

**$ 0.09** 

**$ 0.08** 

**$ 0.03** 

**$ 0.21** 

**$ 0.02** 

**$ 1.43** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0.10 **$ 1.34** 

**$ 1.21** 

**$ 0.47** 

**$ 3.12** 

**$ 0.02** 

**$ 21.63** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 41.16

**$ 27.77** 

**$ 39.20** 

**$ 108.13** 

**$ 0.64** 

**$ 8.98** 

**$ 7.80** 

**$ 2.72** 

**$ 20.14** 

**$ 0.20** 

**$ 128.48** 

**$**

**-**

**$**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:7 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



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

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) System** 

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# 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**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:8 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



# BASE

**TECHNO**

**LOGY**ItemSubsystemSub-Subsystem 

### End Item

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

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) System** 

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# 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**

End Item SG&A Profit ED&T-R&D **Tooling (x1000)**  Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **Net**

**Component/ Assembly**  **Cost Impact to System** 

**ED&T/R&D (x1000)**  

# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Investment (X1000)** 



# 05 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2

E1 **65**

2

F1 **66**

2

G1 **67**

2

H1 **70**

2

I1 **75**

2

J1 **80**

2

K1 **85**

2

L1 **90**SubsystemSub-Subsystem



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

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

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

- $

-

$

-

$



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

**- $** 

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$ **Assembly) (Component** 

**/ Assembly) Cost Impact to** 

**OEM (x1000)** 



### L1 **90**

2 -

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:9 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### M1 **99**

2

N1 **00**

2

**SU**

**BS**

**YS**



# TECHNO

**LOGY**

**PACKAG**SubsystemSub-Subsystem 

### End Item

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

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) System** 

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# 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**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



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

**- $** 

**-**

**$**

**-**

**$**



# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup **Total Markup Total**  **Net**



# 05 **Cy linder Blocks** 

A1 **01**

B1 **02**

C1 **03**

D1 **04**

E1 **65**

F1 **66**

G1 **67**

H1 **70**

I1 **75**

J1 **80**

K1 **85**ItemSubsystemSub-Subsystem



### End Item

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

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

0.09 $ 1.24

$ 1.12

$ 0.44

$ **2.89**

**$**

-

$ **20.30**

**$**

-

$

-

$

-

$

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

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

- $

-

$

-

$

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

0.01 $ 0.10

$ 0.09

$ 0.03

$ **0.23**

**$** 0.02

$ **1.34**

**$**

-

$

-

$

-

$

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

**- $** 

**- $**  **Total Markup**

**Cost (Component/**  **Assembly) Packaging** 

**Cost (Component**  **/ Assembly) Component/** 

**Assembly Cost Impact to** 

**OEM System** 

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 



### K1 **85**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:10 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### L1 **90**

M1 **99**

N1 **00**

**SU**

**BS**

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

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) System** 

**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# 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**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$



### - $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

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



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



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:11 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00**

2 **01**

3 **02**

4 **03**

5 **04** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### -

**$**

**- $** 

**- $** 

**- $** 

**- $**  **Investment(X1 000)** 



### 6 **07**

7 **10**

8 **60**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

14 **99 -** 

**$**

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:12 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### 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:13 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



# BASE

**TECHNO**

**LOGY**ItemSubsystemSub-Subsystem 

### Investment(X1

**000)**



# 05 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2

E1 **65**

2

F1 **66**

2

G1 **67**

2

H1 **70**

2

I1 **75**

2

J1 **80**

2

K1 **85**

2

L1 **90**SubsystemSub-Subsystem



### L1 **90**

2

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:14 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### M1 **99**

2

N1 **00**

2

**SU**

**BS**

**YS**



# TECHNO

**LOGY**

**PACKAG**SubsystemSub-Subsystem 

### Investment(X1

**000)**



# 05 **Cy linder Blocks** 

A1 **01**

B1 **02**

C1 **03**

D1 **04**

E1 **65**

F1 **66**

G1 **67**

H1 **70**

I1 **75**

J1 **80**

K1 **85**ItemSubsystemSub-Subsystem



### K1 **85**

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:15 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### L1 **90**

M1 **99**

N1 **00**

**SU**

**BS**

**YS 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** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00 Vehicle Installation of Power Brake Subsystem (for Hydraulic)**  **0.16 $**  **1.71**

**$ 0.26** 

**$ 2.13** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.13** 

**$**

**-**

**$**



### A Vehicle Installation of Brake Actuation Subsystem Components - Booster 06 07 00

- N0502

- 01 1 Mod. 1 Includes Assembly of Booster Assembly Differences. Base has less assembly content and is

considered baseline. 

### - $ 0.49

$ 0.08

$ **0.56**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **0.56**

**$**

**-**

**$**



### B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum Pump 

### 0.16 $ 1.22

$ 0.19

$ **1.57**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.57**

**$**

**-**

**$**Sub-Subsystem



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponent 

### System

**ED&T/R&D (x1000)**  

# 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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly 

### Name/Description Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# 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)

B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum Pump and Vacuum Hose Assembly. 

### 0.16 $ 1.22

$ 0.19

$ **1.57**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.57**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 2 **01 Vacuum Booster**  **21.15 $**  **13.30**

**$ 18.89** 

**$ 53.33** 

**$ 0.33** 

**$ 4.75** 

**$ 4.09** 

**$ 1.39** 

**$ 10.57** 

**$**

**-**

**$ 63.90** 

**$**

**-**

**$**



### A H Brake Booster Assembly Populated 06 07 01

- N0502

- 01 1 See A.1 1 Master Cylinders were cost neutral - excluded from analysis. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### A1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01

- N0502

- 02 1 Full 1 Unique Boosters between Base and HEV designs 

### 21.15 $ 13.30

$ 18.89

$ **53.33**

**$** 0.33

$ 4.75

$ 4.09

$ 1.39

$ **10.57**

**$**

-

$ **63.90**

**$**

**-**

**$**



### B1 H Nut, Cylinder to Booster 06 07 0

- N0502

- 03 2 na 1 Cost Neutral between Base and

HEV 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 3 **02 Vacuum Pump and Motor**  **22.15 $**  **16.75**

**$ 23.92** 

**$ 62.81** 

**$ 0.36** 

**$ 4.98** 

**$ 4.38** 

**$ 1.59** 

**$ 11.32** 

**$ 0.10** 

**$ 74.23** 

**$**

**-**

**$**



### A H Vacuum Pump Assembly 06 07 02

- N0502

- 01 1 Full 1 Specific to HEV Application 

### 22.15 $ 16.75

$ 23.92

$ **62.81**

**$** 0.36

$ 4.98

$ 4.38

$ 1.59

$ **11.32**

**$** 0.10

$ **74.23**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 4 **03 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5 **04 Hydraulic Booster** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 6 **07 Vacuum Reservoir and Distribution Components** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 8 **60 Wiring Harness Connections**  **3.03 $**  **2.12**

**$ 0.91** 

**$ 6.06** 

**$ 0.03** 

**$ 0.39** 

**$ 0.36** 

**$ 0.15** 

**$ 0.94** 

**$ 0.08** 

**$ 7.08** 

**$**

**-**

**$**



### A Wire Harness Connector - Vacuum Pressure Sensor Brake Booster (4 pin) 

### 06 07 60

- N0502

- 01 1 Full 1 Specific to HEV Application 

### 0.87 $ 0.61

$ 0.26

$ **1.73**

**$** 0.01

$ 0.11

$ 0.10

$ 0.04

$ **0.27**

**$** 0.02

$ **2.02**

**$**

**-**

**$** Wire Harness Connector - Vacuum Pressure Sensor Brake Booster (4 pin) Specific to HEV Application 

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



### B Wire Harness - Vacuum Solenoid, Brake Booster (5 Pin) 

### 06 07 60

- N0502

- 02 1 Full 1 Specific to HEV Application 

### 1.08 $ 0.76

$ 0.32

$ **2.16**

**$** 0.01

$ 0.14

$ 0.13

$ 0.05

$ **0.34**

**$** 0.02

$ **2.52**

**$**

**-**

**$**



### C Wire Harness - Booster Travel Sensor (3 Pin) 

### 06 07 60

- N0502

- 03 1 Full 1 Specific to HEV Application 

### 0.65 $ 0.45

$ 0.19

$ **1.30**

**$** 0.01

$ 0.08

$ 0.08

$ 0.03

$ **0.20**

**$** 0.02

$ **1.52**

**$**

**-**

**$**



### 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&DSub-Subsystem



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponent 

### System

**ED&T/R&D (x1000)**  

# 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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly 

### Name/Description Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM** 

# 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)

D Wire Harness - Vacuum Pump (2 Pin) 06 07 60

- N0502

- 04 1 Full 1 Specific to HEV Application 

### 0.43 $ 0.30

$ 0.13

$ **0.87**

**$** 0.00

$ 0.06

$ 0.05

$ 0.02

$ **0.13**

**$** 0.02

$ **1.02**

**$**

**-**

**$**



### 9 **70 Pipes, Hoses, Ducting**  **1.63 $**  **0.36**

**$ 0.30** 

**$ 2.29** 

**$ 0.01** 

**$ 0.20** 

**$ 0.17** 

**$ 0.06** 

**$ 0.44** 

**$ 0.04** 

**$ 2.77** 

**$**

**-**

**$**



### A H Vacuum Hose Assembly , Vacuum Pump/Intake - Booster 06 07 70

- N0502

- 01 1 Full 1 Specific to HEV Application 

### 1.04 $ 0.11

$ 0.08

$ **1.23**

**$** 0.01

$ 0.09

$ 0.08

$ 0.03

$ **0.21**

**$** 0.02

$ **1.47**

**$**

**-**

**$**



### B H Vacuum Hose Assembly , T - Booster 06 07 0

- N0502

- 02 1 n/a 1 Cost Neutral between Base and HEV. Approx. same tube length to run to -T- (i.e., for HEV) or direct to intake (i.e., Base) 

### 0.59 $ 0.26

$ 0.21

$ **1.06**

**$** 0.01

$ 0.10

$ 0.09

$ 0.03

$ **0.22**

**$** 0.02

$ **1.31**

**$**

**-**

**$**



### 10 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

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



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A H Bolt Vacuum Pump to Block 06 07 80

- N0502

- 01 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation** 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B H Nut Vacuum Pump to Block 06 07 80

- N0502

- 02 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation** 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 48.11 $ 34.24

$ 44.27

$ **126.63**

**$** 0.74

$ 10.32

$ 9.01

$ 3.19

$ **23.26**

**$** 0.22

$ **150.11**

**$**

**-**

**$**



### NOTES:



## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  Complete Subsystem Quote (Yes/No) 

## No

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** 



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00 Vehicle Installation of Power Brake Subsystem (for Hydraulic)** 

A Vehicle Installation of Brake Actuation Subsystem Components - Booster 06 07 00

- N0502

- 01 1 Mod. 1 Includes Assembly of Booster Assembly Differences. Base has less assembly content and is

considered baseline.



### B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum PumpSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# 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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly 

### Name/Description Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) 

# 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)

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum Pump and Vacuum Hose Assembly.



### 2 **01 Vacuum Booster** 

A H Brake Booster Assembly Populated 06 07 01

- N0502

- 01 1 See A.1 1 Master Cylinders were cost neutral - excluded from analysis.



### A1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01

- N0502

- 02 1 Full 1 Unique Boosters between Base and HEV designs



### B1 H Nut, Cylinder to Booster 06 07 0

- N0502

- 03 2 na 1 Cost Neutral between Base and

HEV



### 3 **02 Vacuum Pump and Motor** 

A H Vacuum Pump Assembly 06 07 02

- N0502

- 01 1 Full 1 Specific to HEV Application



### 4 **03 TBD** 

5 **04 Hydraulic Booster** 

6 **07 Vacuum Reservoir and Distribution Components** 

7 **10 TBD** 

8 **60 Wiring Harness Connections** 

A Wire Harness Connector - Vacuum Pressure Sensor Brake Booster (4 pin) 

### 06 07 60

- N0502

- 01 1 Full 1 Specific to HEV Application 

### - **$**

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$** 

### A Wire Harness Connector - Vacuum Pressure Sensor Brake Booster (4 pin) 

### 06 07 60

- N0502

- 01 1 Full 1 Specific to HEV Application



### B Wire Harness - Vacuum Solenoid, Brake Booster (5 Pin) 

### 06 07 60

- N0502

- 02 1 Full 1 Specific to HEV Application



### C Wire Harness - Booster Travel Sensor (3 Pin) 

### 06 07 60

- N0502

- 03 1 Full 1 Specific to HEV Application 

### - **$**

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 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

DRAFTSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# 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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly 

### Name/Description Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) 

# 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)

D Wire Harness - Vacuum Pump (2 Pin) 06 07 60

- N0502

- 04 1 Full 1 Specific to HEV Application



### 9 **70 Pipes, Hoses, Ducting** 

A H Vacuum Hose Assembly , Vacuum Pump/Intake - Booster 06 07 70

- N0502

- 01 1 Full 1 Specific to HEV Application



### B H Vacuum Hose Assembly , T - Booster 06 07 0

- N0502

- 02 1 n/a 1 Cost Neutral between Base and HEV. Approx. same tube length to run to -T- (i.e., for HEV) or direct to intake (i.e., Base)



### 10 **75 Brackets**  **Investment (X1000)**  **Tooling (x1000)** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 11 **80 Boltings** 

A H Bolt Vacuum Pump to Block 06 07 80

- N0502

- 01 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation**



### B H Nut Vacuum Pump to Block 06 07 80

- N0502

- 02 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation**



### 12 **85 Sealing Elements** 

13 **90 Bearings Elements Misc** 

14 **99 Miscellaneous** 

**NOTES:**



## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  Complete Subsystem Quote (Yes/No) 

## No **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### the competing technology

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: **OEM Vehicle 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: Vehicle Installation of Power Brake Subsystem Components - Booster**  

## Part Number: **060700-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


## 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 Vehicle Installation of Power Brake Subsystem

Components 060700-N0502-01-01 **1** Locate and insert Connector (3 Plcs) 

### OEM Vehicle Assembly Not Applicable General Assembly-OEM 

### VO Assembly, OEM, LC **200 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.49**  **$0.08 $0.56**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.56 $0.56**  **$0.00**

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

### 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.

Differences between HEV and Base Pedal Module Installation: **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 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**



### 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 3**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 2**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Differences between HEV and Base Pedal Module Installation: 1. 3 Additional Wiring connection points, Vacuum Pressure Sensor, Vacuum Solenoid, Booster Travel Sensor.

5 **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**

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**



### 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 Vehicle 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: Vehicle Installation of Power Brake Subsystem Components - Booster**  

## Part Number: **060700-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


## 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)**

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**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #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 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #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**



### 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 A **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

3 C **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 

### 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 Vehicle 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: Vehicle Installation of Power Brake Subsystem Components - Booster**  

## Part Number: **060700-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


## 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)**

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

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

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

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

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

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

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

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

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

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

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

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

### "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.

15 O **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**

**Material**

**$0.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.56**

**T1 or OEM Total Manufacturing Cost: $0.00**  **$0.49 $0.08**  **$0.56 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.56**

**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: $0.00**  **$0.49 $0.08**  **$0.56 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.56 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.56** **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** **/ N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******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********R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS: **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 Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm)

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: 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 Cost per Base: 6" Pallet Base, $100/Base



### 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 Vehicle 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: Vehicle Installation of Power Brake Subsystem Components - Booster**  

## Part Number: **060700-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


## 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 Total: $0.000**  

### 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 Vehicle Installation of Power Brake Subsystem Components 060700-N0502-01-01



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

Differences between HEV and Base Pedal Module Installation: 

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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

**$0.49 $0.08**  **$0.56 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Locate and press in Booster Assembly electrical connections, three places. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 18 **1.0 1.0** 

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

- - - - **1.0 2.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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) Differences between HEV and Base Pedal Module Installation: 1. 3 Additional Wiring connection points, Vacuum Pressure Sensor, Vacuum Solenoid, Booster Travel Sensor. **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 3.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 2.0** 

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 12 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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** 



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

A

B

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$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: 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.

D

E

F

G

H

I

J

K

L

M

N

O 

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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

**$0.00**

**$0.00**

**$0.00**

**$0.00** O

**$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**

**$0.49 $0.08**  **$0.56 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.56 2** 



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



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 8 of 12 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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 Vehicle Installation of Power Brake Subsystem Components 060700-N0502-01-01



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

Differences between HEV and Base Pedal Module Installation:**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** 

**200 18.00**  1.00

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

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

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

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

-



## Purchase Part - High Impact Item (Full Cost Mapping) Differences between HEV and Base Pedal Module Installation: 1. 3 Additional Wiring connection points, Vacuum Pressure Sensor, Vacuum Solenoid, Booster Travel Sensor. **#DIV/0! #DIV/0!** 

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

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

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

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

-

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

-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-

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

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

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

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

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

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

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

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

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

-
**#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!** 

-



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

A

B

C **#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.

D

E

F

G

H

I

J

K

L

M

N

O**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** 

O



### 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 6 

# 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** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00 Vehicle Installation of Power Brake Subsystem (for Hydraulic)** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A Vehicle Installation of Brake Actuation Subsystem Components - Booster 06 07 00

- N0502

- 01 1 Mod. 1 Includes Assembly of Booster Assembly Diffferences. Base has less assembly content and is

considered baseline. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum Pump



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$ Total**  **Packaging**

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM System** 

**ED&T/R&D (x1000)**  

### Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) **Total Markup**

**Cost (Component/**  **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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# 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)

B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum Pump and Vacuum Hose Assembly. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 2 **01 Vacuum Booster**  **21.15 $**  **13.30**

**$ 18.89** 

**$ 53.33** 

**$ 0.33** 

**$ 4.75** 

**$ 4.09** 

**$ 1.39** 

**$ 10.57** 

**$**

**-**

**$ 63.90** 

**$**

**-**

**$**



### A.1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01

- N0502

- 02 1 Full 1 Unique Boosters between Base and HEV designs 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### A.2 H - Pressure Sensor 3.85 $ 1.02

$ 2.55

$ **7.42**

**$** 0.05

$ 0.73

$ 0.62

$ 0.20

$ **1.59**

**$**

-

$ **9.02**

**$**

**-**

**$**



### A.3 H Position Sensor 1.47 $ 1.06

$ 2.41

$ **4.94**

**$** 0.04

$ 0.56

$ 0.46

$ 0.13

$ **1.20**

**$**

-

$ **6.14**

**$**

**-**

**$**



### A.4 H-Solenoid, Booster 4.45 $ 1.32

$ 4.29

$ **10.06**

**$** 0.07

$ 1.10

$ 0.91

$ 0.27

$ **2.36**

**$**

-

$ **12.42**

**$**

**-**

**$**



### A.5 H-Brake Booster Assy, Populated

- $ 0.62

$ 0.24

$ **0.86**

**$** 0.00

$ 0.06

$ 0.05

$ 0.02

$ **0.13**

**$**

-

$ **1.00**

**$**

**-**

**$**



### A.6 H-Vacuum Hose Fitting 0.10 $ 0.10

$ 0.10

$ **0.30**

**$** 0.00

$ 0.04

$ 0.03

$ 0.01

$ **0.08**

**$**

-

$ **0.38**

**$**

**-**

**$**



### A.7 H-Brake Booster Assembly 0.33 $ 0.74

$ 0.29

$ **1.36**

**$** 0.01

$ 0.09

$ 0.08

$ 0.03

$ **0.21**

**$**

-

$ **1.57**

**$**

**-**

**$**



### A.8 H-Rear Shell w. Plates 0.52 $ 1.82

$ 0.71

$ **3.05**

**$** 0.02

$ 0.21

$ 0.19

$ 0.08

$ **0.49**

**$**

-

$ **3.54**

**$**

**-**

**$**



### A.9 H-Rear Shell w. Studs 1.62 $ 0.21

$ 0.57

$ **2.40**

**$** 0.01

$ 0.16

$ 0.14

$ 0.06

$ **0.37**

**$**

-

$ **2.77**

**$**

**-**

**$**



### A.10 H-Stud Plate, Rear Shell 0.12 $ 0.17

$ 1.17

$ **1.46**

**$** 0.01

$ 0.09

$ 0.09

$ 0.04

$ **0.23**

**$**

-

$ **1.69**

**$**

**-**

**$**



### A.11 H-Clevis to Pedal 0.00 $ 0.16

$ 0.13

$ **0.29**

**$** 0.00

$ 0.03

$ 0.02

$ 0.01

$ **0.06**

**$**

-

$ **0.36**

**$**

**-**

**$**



### A.12 H-Support Clevis to Pedal, Plate 0.24 $ 0.14

$ 0.79

$ **1.17**

**$** 0.01

$ 0.16

$ 0.13

$ 0.04

$ **0.33**

**$**

-

$ **1.50**

**$**

**-**

**$**



### A.13 H-Center Section, Booster 0.00 $ 0.41

$ 0.16

$ **0.57**

**$** 0.00

$ 0.05

$ 0.04

$ 0.01

$ **0.11**

**$**

-

$ **0.68**

**$**

**-**

**$**



### A.14 H-Plates and Diaphragms 0.90 $ 0.13

$ 0.25

$ **1.29**

**$** 0.01

$ 0.12

$ 0.10

$ 0.03

$ **0.26**

**$**

-

$ **1.55**

**$**

**-**

**$**



### A.15 H-Valve Body w. Seals 0.32 $ 0.12

$ 0.22

$ **0.66**

**$** 0.00

$ 0.07

$ 0.06

$ 0.02

$ **0.15**

**$**

-

$ **0.81**

**$**

**-**

**$**



### A.16 H-Rear Plate, Dia. Cup 0.92 $ 0.23

$ 0.42

$ **1.57**

**$** 0.01

$ 0.13

$ 0.12

$ 0.04

$ **0.30**

**$**

-

$ **1.87**

**$**

**-**

**$**



### A.17 H-Center Plate w. Seal 0.76 $ 0.14

$ 0.20

$ **1.10**

**$** 0.01

$ 0.08

$ 0.07

$ 0.03

$ **0.18**

**$**

-

$ **1.28**

**$**

**-**

**$**



### A.18 H-Connector, Input Rod to Solen 0.27 $ 0.21

$ 0.14

$ **0.62**

**$** 0.00

$ 0.07

$ 0.06

$ 0.02

$ **0.15**

**$**

-

$ **0.78**

**$**

**-**

**$**



### A.19 H-Input Rod Assembly 0.74 $ 0.91

$ 0.86

$ **2.52**

**$** 0.01

$ 0.17

$ 0.16

$ 0.06

$ **0.41**

**$**

-

$ **2.92**

**$**

**-**

**$**



### A.20 H-Key Booster 0.08 $ 0.06

$ 0.02

$ **0.16**

**$** 0.00

$ 0.02

$ 0.02

$ 0.01

$ **0.05**

**$**

-

$ **0.21**

**$**

**-**

**$**



### A.21 H-Reaction Disk Assembly 0.15 $ 0.63

$ 0.86

$ **1.64**

**$** 0.01

$ 0.12

$ 0.11

$ 0.04

$ **0.27**

**$**

-

$ **1.91**

**$**

**-**

**$**



### A.22 H-Output Rod Assembly 0.14 $ 0.65

$ 1.00

$ **1.80**

**$** 0.01

$ 0.12

$ 0.11

$ 0.04

$ **0.28**

**$**

-

$ **2.08**

**$**

**-**

**$**



### A.23 H-Solenoid, w. Seal Booster 0.03 $ 0.05

$ 0.08

$ **0.16**

**$** 0.00

$ 0.02

$ 0.02

$ 0.00

$ **0.04**

**$**

-

$ **0.20**

**$**

**-**

**$**



### A.24 H-Frt Shell Assy, Brake Booster 2.38 $ 2.20

$ 0.86

$ **5.43**

**$** 0.03

$ 0.40

$ 0.36

$ 0.14

$ **0.93**

**$**

-

$ **6.36**

**$** H-Frt Shell Assy, Brake Booster $ **$ $**  $ **$**

**- $** 



### A.25 H-Front Sheel Assy, Painted 1.76 $ 0.20

$ 0.54

$ **2.50**

**$** 0.01

$ 0.16

$ 0.15

$ 0.06

$ **0.39**

**$**

-

$ **2.89**

**$**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

# 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 **Total Packaging** 

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM System** 

**ED&T/R&D (x1000)**  

### Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) **Total Markup**

**Cost (Component/**  **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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# 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)

3 **02 Vacuum Pump and Motor** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A H Vacuum Pump Assembly 06 07 02

- N0502

- 01 1 Full 1 Specific to HEV Application



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 4 **03 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5 **04 Hydraulic Booster** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

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



### 6 **07 Vacuum Reservoir and Distribution Components** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 8 **60 Wiring Harness Connections** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A Wire Harness Connector - Vacuum Sensor Brake Booster 

### 06 07 60

- N0502

- 01 1 Full 1 Specific to HEV Application



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B Wire Harness - Vacuum Solenoid, Brake Booster 

### 06 07 60

- N0502

- 02 1 Full 1 Specific to HEV Application



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### C Wire Harness - Booster Travel Sensor 

### 06 07 60

- N0502

- 03 1 Full 1 Specific to HEV Application



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 9 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A H Vacuum Hose Assembly , Vacuum Pump/Intake - Booster 06 07 70

- N0502

- 01 1 Full 1 Specific to HEV Application



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B H Vacuum Hose Assembly , T - Booster 06 07 0

- N0502

- 02 1 n/a 1 Cost Neutral between Base and HEV. Approx. same tube length to run to -T- (i.e., for HEV) or direct to intake (i.e., Base) 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 10 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A H Bolt Vacuum Pump to Block 06 07 80

- N0502

- 01 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation** 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B H Nut Vacuum Pump to Block 06 07 80

- N0502

- 02 1 na 1 Specific to HEV Application



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

### B H Nut Vacuum Pump to Block 06 07 80

- N0502

- 02 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation** 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

# 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 **Total Packaging** 

**Cost (Component**  **/ Assembly) Net** 

**Component/ Assembly**  **Cost Impact to**

**OEM System** 

**ED&T/R&D (x1000)**  

### Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) **Total Markup**

**Cost (Component/**  **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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# 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)

12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 21.15 $ 13.30

$ 18.89

$ **53.33**

**$** 0.33

$ 4.75

$ 4.09

$ 1.39

$ **10.57**

**$**

-

$ **63.90**

**$**

**-**

**$**



### NOTES:



## 1. **No** Complete Subsystem Quote

(Yes/No)

**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology** 

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

# 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** 



# 060700 Pow **er Brake Subsy stem ( for Hy**  **draulics)**

1 **00 Vehicle Installation of Power Brake Subsystem (for Hydraulic)** 

A Vehicle Installation of Brake Actuation Subsystem Components - Booster 06 07 00

- N0502

- 01 1 Mod. 1 Includes Assembly of Booster Assembly Diffferences. Base has less assembly content and is

considered baseline.



### B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum Pump 

### Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) 

# 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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00

- N0502

- 01 1 Full 1 Includes Assembly of Vacuum Pump and Vacuum Hose Assembly.



### 2 **01 Vacuum Booster** 

A.1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01

- N0502

- 02 1 Full 1 Unique Boosters between Base and HEV designs 

### A.2 H - Pressure Sensor

A.3 H Position Sensor

A.4 H-Solenoid, Booster

A.5 H-Brake Booster Assy, Populated

A.6 H-Vacuum Hose Fitting

A.7 H-Brake Booster Assembly

A.8 H-Rear Shell w. Plates

A.9 H-Rear Shell w. Studs

A.10 H-Stud Plate, Rear Shell

A.11 H-Clevis to Pedal

A.12 H-Support Clevis to Pedal, Plate

A.13 H-Center Section, Booster

A.14 H-Plates and Diaphragms

A.15 H-Valve Body w. Seals

A.16 H-Rear Plate, Dia. Cup

A.17 H-Center Plate w. Seal

A.18 H-Connector, Input Rod to Solen

A.19 H-Input Rod Assembly

A.20 H-Key Booster

A.21 H-Reaction Disk Assembly

A.22 H-Output Rod Assembly

A.23 H-Solenoid, w. Seal Booster

A.24 H-Frt Shell Assy, Brake Booster **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### A.24 H-Frt Shell Assy, Brake Booster

A.25 H-Front Sheel Assy, Painted **- $** 

**-**

**$**

**- $** 

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) 

# 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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

3 **02 Vacuum Pump and Motor** 

A H Vacuum Pump Assembly 06 07 02

- N0502

- 01 1 Full 1 Specific to HEV Application



### 4 **03 TBD** 

5 **04 Hydraulic Booster**  **Investment (X1000)**  **Tooling (x1000)** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 6 **07 Vacuum Reservoir and Distribution Components** 

7 **10 TBD** 

8 **60 Wiring Harness Connections** 

A Wire Harness Connector - Vacuum Sensor Brake Booster 

### 06 07 60

- N0502

- 01 1 Full 1 Specific to HEV Application



### B Wire Harness - Vacuum Solenoid, Brake Booster 

### 06 07 60

- N0502

- 02 1 Full 1 Specific to HEV Application



### C Wire Harness - Booster Travel Sensor 

### 06 07 60

- N0502

- 03 1 Full 1 Specific to HEV Application



### 9 **70 Pipes, Hoses, Ducting** 

A H Vacuum Hose Assembly , Vacuum Pump/Intake - Booster 06 07 70

- N0502

- 01 1 Full 1 Specific to HEV Application



### B H Vacuum Hose Assembly , T - Booster 06 07 0

- N0502

- 02 1 n/a 1 Cost Neutral between Base and HEV. Approx. same tube length to run to -T- (i.e., for HEV) or direct to intake (i.e., Base)



### 10 **75 Brackets** 

11 **80 Boltings** 

A H Bolt Vacuum Pump to Block 06 07 80

- N0502

- 01 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation**



### B H Nut Vacuum Pump to Block 06 07 80

- N0502

- 02 1 na 1 Specific to HEV Application 

### - **$**

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$** 

### B H Nut Vacuum Pump to Block 06 07 80

- N0502

- 02 1 na 1 Specific to HEV Application **PIA to Vacuum pump Installation** 

### - **$**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/30/2012

DRAFT

Full, Modification, Differential,

or Not Applicable
Quote Level Scaling

Factor (Default =1) 

# 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 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

12 **85 Sealing Elements** 

13 **90 Bearings Elements Misc** 

14 **99 Miscellaneous**  **Investment (X1000)**  **Tooling (x1000)** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### NOTES:



## 1. **No** Complete Subsystem Quote

(Yes/No)

**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  **- $** 

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# 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 Vacuum Hose Assembly,Booster**  

## Part Number: **060770-N0502-01** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

**Burden**

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

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

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

### End

**Item Scrap** 

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

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

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

**R&D**

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

**Mark**

**up Rate**  **Total**

**Mark**

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

### Material

A 

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

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

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

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

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

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

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

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** 

### 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)**

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**



### 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**



### 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 H-VACUUM HOSE ASSEMBLY, BOOSTER 060770-N0502-01 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **180 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.11**  **$0.08 $0.19**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.21 $0.21**  **$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**



### 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 HOSE CLIP 060770-N0502-02 **2** S **$0.00** $0.03 **$0.00 $0.06**  **$0.06**

HOSE CLIP 060770-N0502-02

2 HOSE 5/16 VL OUTER - CR INNER - NBR (

28") Total 060770-N0502-03 **1** 0.42 @ $1.85/lb. S **$0.00** $0.78 **$0.00 $0.78**  **$0.78**

3 CONVOLUTE (20.5 ") 19mm 060770-N0502-04 **1** .12/ft. S **$0.00** $0.21 **$0.00 $0.21**  **$0.21**

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

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

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

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

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

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

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

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for
Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.



### File: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 6 

# 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 Vacuum Hose Assembly,Booster**  

## Part Number: **060770-N0502-01** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material**

**$1.04**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.25**

**T1 or OEM Total Manufacturing Cost: $1.04**  **$0.11 $0.08**  **$1.23 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  **$1.25**

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

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

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

----- ----- ----- **$0.01 $0.08**  **$0.08 $0.03**  **$0.19**

**Base Cost Impact to Vehicle: $1.04**  **$0.11 $0.08**  **$1.23 $0.01**  **$0.09 $0.08**  **$0.03 $0.21**  **$1.45 $0**  **$0**

**Packaging Cost: $0.02** 

**3 1** 



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

**Net Cost Impact to Vehicle: $1.47** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

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

H-VACUUM HOSE ASSEMBLY, BOOSTER 060770-N0502-01



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

HOSE CLIP 060770-N0502-02 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.11 $0.08**  **$0.19 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Bend, cut, slide on convulte tube and apply two clamps **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 20 4 1 20 **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.06** HOSE CLIP 060770-N0502-02

HOSE 5/16 VL OUTER - CR INNER - NBR ( 28") Total 060770-N0502-03

CONVOLUTE (20.5 ") 19mm 060770-N0502-04 **$0.06**

**$0.78**

**$0.21**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$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: 4 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

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

**Total**

**$0.11 $0.08**  **$1.23 $0.00**  **$0.01 $0.01**  **$0.00 $0.02** 

**$1.25 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: 5 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

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

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

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

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

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

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

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

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

-



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

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

H-VACUUM HOSE ASSEMBLY, BOOSTER 060770-N0502-01



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

HOSE CLIP 060770-N0502-02 **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

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

-

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

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

-

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

-

**180 20.00**  0.50

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

-

HOSE CLIP 060770-N0502-02

HOSE 5/16 VL OUTER - CR INNER - NBR ( 28") Total 060770-N0502-03

CONVOLUTE (20.5 ") 19mm 060770-N0502-04



### 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 6 

# 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 6 

# 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: Wire Harness Connector - Vacuum Sensor Brake Booster**  

## Part Number: **060760-N0502-01** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

**Burden**

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

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

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

### End

**Item Scrap** 

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

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

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

**R&D**

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

**Mark**

**up Rate**  **Total**

**Mark**

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

### Material

A 

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

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

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

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

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

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

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

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** 

### 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** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 H-SOLENOID, BOOSTER 060701-N0502-85 **1** Assemble T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, LC **120 2**  **2 1**  0.000 **$0.00 $36.21**  **$100.00 $200.00**  **$0.00 $0.60**  **$1.67 $2.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.23**  **$2.50 $2.50**  **$0.00**

2 H-RELAY, PISTON,SOLENOID 060701-N0502-86 **1** Assemble T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, LC **360 0.5**  **1 1**  0.000 **$0.00 $36.21**  **$100.00 $100.00**  **$0.00 $0.05**  **$0.28 $0.33**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.36 $0.36**  **$0.00**

3 H-SOLENOID HOUSING, BOOSTER 060701-N0502-87 **1** Wash T2/T3 Stamp/Form, SSLC Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.12 $0.12**  **$0.00**

4 H-SOLENOID HOUSING, BOOSTER 060701-N0502-87A **1** Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LMC,

Automatic Load **135 0.5**  **3 1**  0.000 **$0.00 $36.98**  **$46.82 $140.46**  **$0.00 $0.14**  **$1.04 $1.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.12**  **$1.30 $1.30**  **$0.00**

5 H-SOLENOID HOUSING, BOOSTER 060701-N0502-87B **1** Stamp T2/T3 Stamp/Form, SSLC PM-SMF-SS410 Cut/Punch/Forming Operator Stamp/Form, SS **3000 0.5**  **1 1**  0.159 **$4.50 $42.73**  **$42.91 $42.91**  **$0.72 $0.01**  **$0.01 $0.74**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.08**  **$0.81 $0.81**  **$0.72**

6 H-SOLENOID CAP, BOOSTER 060701-N0502-88 **1** Wash T2/T3 Stamp/Form, SSLC Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.12 $0.12**  **$0.00**

7 H-SOLENOID CAP, BOOSTER 060701-N0502-88A **1** Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LMC,

Automatic Load **166 1**  **3 1**  0.000 **$0.00 $36.98**  **$46.82 $140.46**  **$0.00 $0.22**  **$0.85 $1.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.11**  **$1.18 $1.18**  **$0.00**

8 H-SOLENOID CAP, BOOSTER 060701-N0502-88C **1** Stamp T2/T3 Stamp/Form, SSLC PM-SMF-SS410 Cut/Punch/Forming Operator Stamp/Form, SS **4500 0.5**  **1 1**  0.080 **$4.50 $42.73**  **$42.91 $42.91**  **$0.36 $0.00**  **$0.01 $0.37**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.41 $0.41**  **$0.36**

9 H-RELAY, PISTON,SOLENOID 060701-N0502-89 **1** Wash T2/T3 Stamp/Form, SSLC Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.12 $0.12**  **$0.00**

10 H-RELAY, PISTON,SOLENOID 060701-N0502-89A **1** Machine T2/T3 CNC Turning, SSLC MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA **195 1**  **2 1**  0.070 **$0.74 $36.98**  **$20.48 $40.96**  **$0.05 $0.19**  **$0.21 $0.45**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.50 $0.50**  **$0.05**

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**



### 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**



### 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 

### Connector 060701-N0502-90 **1** S **$0.00** $1.50 **$0.00 $1.50**  **$1.50**

2 

### Coil 060701-N0502-91 **1** S **$0.00** $1.75 **$0.00 $1.75**  **$1.75**

3 

### Seal- inner 060701-N0502-92 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

4 

### Brass Insert - Relay Valve Piston 060701-N0502-93 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

5 

### Brass Insert - Relay Valve Piston 060701-N0502-94 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

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

7 **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.



### 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 6 

# 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: Wire Harness Connector - Vacuum Sensor Brake Booster**  

## Part Number: **060760-N0502-01** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

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

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

**Material**

**$4.45**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **#REF!**

**T1 or OEM Total Manufacturing Cost: $4.45**  **$1.32 $4.29**  **$10.06 $0.02**  **$0.40 $0.27**  **$0.00 $0.69**  **$10.75**

**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 $0.70**  **$0.65 $0.27**  **$1.67** 

### "Alpha

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

**3 1** 



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

**Base Cost Impact to Vehicle: $4.45**  **$1.32 $4.29**  **$10.06 $0.07**  **$1.10 $0.91**  **$0.27 $2.36**  **$12.42 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $12.42** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-SOLENOID, BOOSTER 060701-N0502-85

H-RELAY, PISTON,SOLENOID 060701-N0502-86

H-SOLENOID HOUSING, BOOSTER 060701-N0502-87

H-SOLENOID HOUSING, BOOSTER 060701-N0502-87A

H-SOLENOID HOUSING, BOOSTER 060701-N0502-87B

H-SOLENOID CAP, BOOSTER 060701-N0502-88

H-SOLENOID CAP, BOOSTER 060701-N0502-88A

H-SOLENOID CAP, BOOSTER 060701-N0502-88C

H-RELAY, PISTON,SOLENOID 060701-N0502-89

H-RELAY, PISTON,SOLENOID 060701-N0502-89A



## 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** 

**$0.60 $1.67**  **$2.27 $0.01**  **$0.14 $0.09**  **$0.00 $0.23**  Apply adhesive to cap and attach connector and coil asm. Place waher and piston in housing, place cap on it and crimp. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 60 **1.0 2.0** 

**$0.05 $0.28**  **$0.33 $0.00**  **$0.02 $0.01**  **$0.00 $0.03** 

Two Brass inserts placed at in each end of the relay piston **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 10 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 13 **1.0 1.0** 

**$0.14 $1.04**  **$1.18 $0.00**  **$0.07 $0.05**  **$0.00 $0.12**  EC-400 - Pallet Size 400 mm square, 1000 lb Capacity **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 80 **1.0 3.0** 

**$0.01 $0.01**  **$0.74 $0.00**  **$0.04 $0.03**  **$0.00 $0.08**  200-400 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 1.2 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 13 **1.0 1.0** 

**$0.22 $0.85**  **$1.07 $0.00**  **$0.06 $0.04**  **$0.00 $0.11**  EC-400 - Pallet Size 400 mm square, 1000 lb Capacity **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 65 **1.0 3.0** 

**$0.00 $0.01**  **$0.37 $0.00**  **$0.02 $0.01**  **$0.00 $0.04**  200-400 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 0.8 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 13 **1.0 1.0** 

**$0.19 $0.21**  **$0.45 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 37 **1.0 2.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

Connector 060701-N0502-90



### Coil 060701-N0502-91


### Seal- inner 060701-N0502-92 

### Brass Insert - Relay Valve Piston 060701-N0502-93 

### Brass Insert - Relay Valve Piston 060701-N0502-94 **$1.50**

**$1.75**

**$0.03**

**$0.02**

**$0.02**

**$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: 4 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

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

**Total**

**$1.32 $4.29**  **$10.06 $0.02**  **$0.40 $0.27**  **$0.00 $0.69** 

**$10.75 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: 5 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

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

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

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

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

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

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

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

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

-



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

H-SOLENOID, BOOSTER 060701-N0502-85

H-RELAY, PISTON,SOLENOID 060701-N0502-86

H-SOLENOID HOUSING, BOOSTER 060701-N0502-87

H-SOLENOID HOUSING, BOOSTER 060701-N0502-87A

H-SOLENOID HOUSING, BOOSTER 060701-N0502-87B

H-SOLENOID CAP, BOOSTER 060701-N0502-88

H-SOLENOID CAP, BOOSTER 060701-N0502-88A

H-SOLENOID CAP, BOOSTER 060701-N0502-88C

H-RELAY, PISTON,SOLENOID 060701-N0502-89

H-RELAY, PISTON,SOLENOID 060701-N0502-89A



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

-

**120 30.00**  2.00

**360 10.00**  0.50

**277 13.00**  0.25

**135 26.67**  0.50

**3000 1.20**  0.50

**277 13.00**  0.25

**166 21.67**  1.00

**4500 0.80**  0.50

**277 13.00**  0.25

**195 18.50**  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!** 

-



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

Connector 060701-N0502-90



### Coil 060701-N0502-91


### Seal- inner 060701-N0502-92 

### Brass Insert - Relay Valve Piston 060701-N0502-93 

### Brass Insert - Relay Valve Piston 060701-N0502-94



### 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 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

**Burden**

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

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

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

### End

**Item Scrap** 

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

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

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

**R&D**

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

**Mark**

**up Rate**  **Total**

**Mark**

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

### Material

A 

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

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

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

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

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

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

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

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** 

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



### B 

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

1 H-PRESSURE SENSOR, FRONT SHELL 060701-N0502-95 **1** Assemble T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, LC **120 2**  **2 1**  0.000 **$0.00 $36.21**  **$100.00 $200.00**  **$0.00 $0.60**  **$1.67 $2.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.23**  **$2.50 $2.50**  **$0.00**

2 BOARD/SENSOR ASM 060701-N0502-96 **2** Assemble T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, LC **240 1**  **1 1**  0.000 **$0.00 $36.21**  **$100.00 $100.00**  **$0.00 $0.15**  **$0.42 $0.57**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.63 $1.25**  **$0.00**

3 CERAMIC SENSOR/O-RING FRAME 060701-N0502-96 **2** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **4500 1**  **1 1**  0.001 **$1.74 $41.48**  **$16.39 $16.39**  **$0.00 $0.01**  **$0.00 $0.01**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.02 $0.03**  **$0.00**

4 BOARD/CERAMIC SENSOR CAP 060701-N0502-97 **2** Stamp T2/T3 Stamp/Form, SSLC S-Steel-304, Coil Cut/Punch/Forming Operator 

### Stamp/Form, Terminals **4500 0.5**  **1 1**  0.002 **$1.64 $42.73**  **$15.50 $15.50**  **$0.00 $0.00**  **$0.00 $0.01**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.01 $0.03**  **$0.01**

5 BOARD/CERAMIC SENSOR HOUSING 060701-N0502-98 **2** Stamp T2/T3 Stamp/Form, SSLC S-Steel-304, Coil Cut/Punch/Forming Operator 

### Stamp/Form, Terminals **4500 0.5**  **1 1**  0.010 **$1.64 $42.73**  **$15.50 $15.50**  **$0.02 $0.00**  **$0.00 $0.02**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.03 $0.05**  **$0.03**

6 HOUSING, PRESSURE SENSOR 060701-N0502-99 **1** Mold T2/T3 Inject. Mold, SSLC Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1200 1**  **1 1**  0.050 **$1.76 $41.48**  **$16.39 $16.39**  **$0.09 $0.03**  **$0.01 $0.14**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.15 $0.15**  **$0.09**

7 CAP, PRESSURE SENSOR 060701-N0502-100 **1** Mold T2/T3 Inject. Mold, SSLC Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.007 **$1.76 $41.48**  **$16.39 $16.39**  **$0.01 $0.02**  **$0.01 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.05 $0.05**  **$0.01**

8 SIDE COVER, PRESSURE SENSOR 060701-N0502-101 **1** Mold T2/T3 Inject. Mold, SSLC Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.001 **$1.76 $41.48**  **$16.39 $16.39**  **$0.00 $0.02**  **$0.01 $0.03**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04**  **$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**



### C 

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

1 **0 180**  **0.25 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 1800**  **1 1**  **1** 0.015 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 1800**  **1 1**  **1** 0.015 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 CERAMIC PLATE, PRESSURE SENSOR **2** S **$0.00** $0.75 **$0.00 $1.50**  **$1.50** 

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

Assembly.



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

3 BOARD, PRESSURE SENSOR **2** S **$0.00** $1.00 **$0.00 $2.00**  **$2.00**

4 ADHESIVE, PRESSURE SENSOR **2** S **$0.00** $0.015 **$0.00 $0.03**  **$0.03**

5 O-RING, PRESSURE SENSOR **2** S **$0.00** $0.01 **$0.00 $0.02**  **$0.02**

6 CONNECTOR HARDWARE, PRESSURE SENSOR **1** S **$0.00** $0.15 **$0.00 $0.15**  **$0.15**

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

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

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

**Material**

**$3.85**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total $7.81**  

### "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

**1 Material**  **Labor Burden**  **TMC Scrap**  **SG&A Profit**  **ED&T Mark-up**  **$7.81**

**T1 or OEM Total Manufacturing Cost: $3.85**  **$1.02 $2.55**  **$7.42 $0.01**  **$0.22 $0.15**  **$0.00 $0.38**  **$7.81**

**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**

----- ----- ----- **$0.04 $0.51**  **$0.47 $0.20**  **$1.21**

**Base Cost Impact to Vehicle: $3.85**  **$1.02 $2.55**  **$7.42 $0.05**  **$0.73 $0.62**  **$0.20 $1.59**  **$9.02 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $9.02** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **3 1** 



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



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-PRESSURE SENSOR, FRONT SHELL 060701-N0502-95

BOARD/SENSOR ASM 060701-N0502-96

CERAMIC SENSOR/O-RING FRAME 060701-N0502-96

BOARD/CERAMIC SENSOR CAP 060701-N0502-97

BOARD/CERAMIC SENSOR HOUSING 060701-N0502-98

HOUSING, PRESSURE SENSOR 060701-N0502-99

CAP, PRESSURE SENSOR 060701-N0502-100

SIDE COVER, PRESSURE SENSOR 060701-N0502-101 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.60 $1.67**  **$2.27 $0.01**  **$0.14 $0.09**  **$0.00 $0.23**  Apply adhesive, place sensor into housing. Repeat for second sensor. Solder connections. Apply adhesive and place cap and side cover on housing. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 60 **1.0 2.0** 

**$0.30 $0.83**  **$1.14 $0.00**  **$0.07 $0.05**  **$0.00 $0.12**  Place o-ring and ceramic plate into plastic frame. Insert into housing and place boardonto plate.Solder connections and place cap onto housing. Crimp to secure. **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98**

- - 2 30 **1.0 1.0** 

**$0.02 $0.01**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton , 10 cavity mold **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98**

- - 10 8 **1.0 1.0** 

**$0.01 $0.01**  **$0.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Progessive 0-60 ton **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98**

- - 1 0.8 **1.0 1.0** 

**$0.01 $0.01**  **$0.05 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  Progessive 0-60 ton **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98**

- - 1 0.8 **1.0 1.0** 

**$0.03 $0.01**  **$0.14 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  55-150 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 4 12 **1.0 1.0** 

**$0.02 $0.01**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 4 8 **1.0 1.0** 

**$0.02 $0.01**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 4 8 **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

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

CERAMIC PLATE, PRESSURE SENSOR **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Insert valve, apply adhesive and press base to cover **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** 20 2 1 20 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton, 10 cavity mold **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** 2 1 10 20 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** 2 1 10 20 **1.0 1.0** 

**$0.00**

**$1.50**



### 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 6 

# 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.

BOARD, PRESSURE SENSOR

ADHESIVE, PRESSURE SENSOR

O-RING, PRESSURE SENSOR

CONNECTOR HARDWARE, PRESSURE SENSOR 

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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

**$2.00**

**$0.03**

**$0.02**

**$0.15**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$1.02 $2.55**  **$7.42 $0.01**  **$0.22 $0.15**  **$0.00 $0.38** 

**$7.81 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: 5 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

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

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

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

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

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

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

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

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

-



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

H-PRESSURE SENSOR, FRONT SHELL 060701-N0502-95

BOARD/SENSOR ASM 060701-N0502-96

CERAMIC SENSOR/O-RING FRAME 060701-N0502-96

BOARD/CERAMIC SENSOR CAP 060701-N0502-97

BOARD/CERAMIC SENSOR HOUSING 060701-N0502-98

HOUSING, PRESSURE SENSOR 060701-N0502-99

CAP, PRESSURE SENSOR 060701-N0502-100

SIDE COVER, PRESSURE SENSOR 060701-N0502-101 **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

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

-

**120 30.00**  2.00

**240 15.00**  1.00

**4500 0.80**  1.00

**4500 0.80**  0.50

**4500 0.80**  0.50

**1200 3.00**  1.00

**1800 2.00**  1.00

**1800 2.00**  1.00

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

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

-



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

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

CERAMIC PLATE, PRESSURE SENSOR **180 20.00**  0.25

**1800 2.00**  1.00

**1800 2.00**  1.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# 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.

BOARD, PRESSURE SENSOR

ADHESIVE, PRESSURE SENSOR

O-RING, PRESSURE SENSOR

CONNECTOR HARDWARE, PRESSURE SENSOR**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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

**Burden**

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

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

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

### End

**Item Scrap** 

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

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

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

**R&D**

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

**Mark**

**up Rate**  **Total**

**Mark**

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

### Material

A 

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

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

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

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

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

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

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

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** 

### 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)**

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**



### B 

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

1 H-POSITION SENSOR, FRONT SHELL 060701-N0502-102 **1** Assemble T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, LC **120 2**  **2 1**  0.000 **$0.00 $36.21**  **$100.00 $200.00**  **$0.00 $0.60**  **$1.67 $2.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.23**  **$2.50 $2.50**  **$0.00**

2 SHAFT and CARRIER ASM 060701-N0502-131 **1** Assemble T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, LC **180 1**  **1 1**  0.000 **$0.00 $36.21**  **$100.00 $100.00**  **$0.00 $0.20**  **$0.56 $0.76**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.08**  **$0.83 $0.83**  **$0.00**

3 CARRIER, WIPER CONTACT 060701-N0502-104 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.002 **$1.74 $41.48**  **$16.39 $16.39**  **$0.00 $0.02**  **$0.01 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04**  **$0.00**

3 SHAFT ASM w CAP 060701-N0502-105 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.002 **$1.74 $41.48**  **$16.39 $16.39**  **$0.00 $0.02**  **$0.01 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04**  **$0.00**

4 SHAFT, POSITION SENSOR 060701-N0502-106 **1** Machine T2/T3 CNC Turning, SSLC S-Steel-304, Bar CNC Operator CNC Turning, SS, BF, DA **144 0.5**  **1 1**  0.010 **$1.65 $36.98**  **$20.48 $20.48**  **$0.02 $0.13**  **$0.14 $0.29**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.32 $0.32**  **$0.02**

5 HOUSING, POSITION SENSOR 060701-N0502-107 **1** Mold T2/T3 Inject. Mold, SSLC Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1200 1**  **1 1**  0.058 **$1.76 $41.48**  **$16.39 $16.39**  **$0.10 $0.03**  **$0.01 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.17 $0.17**  **$0.10**

6 CAP, POSITION SENSOR 060701-N0502-108 **1** Mold T2/T3 Inject. Mold, SSLC Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.003 **$1.76 $41.48**  **$16.39 $16.39**  **$0.00 $0.02**  **$0.01 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04**  **$0.00**

7 SHAFT RETAINER, MOLDED - POSITION

SENSOR 060701-N0502-109 **1** Mold T2/T3 Inject. Mold, SSLC Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.004 **$1.76 $41.48**  **$16.39 $16.39**  **$0.01 $0.02**  **$0.01 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04**  **$0.01**

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**



### C 

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

1 **0 180**  **0.25 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 1800**  **1 1**  **1** 0.015 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 1800**  **1 1**  **1** 0.015 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 SPRING, POSITION SENSOR 060701-N0502-110 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05** 

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

Assembly.



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

3 BOARD, POSITION SENSOR 060701-N0502-111 **1** S **$0.00** $1.00 **$0.00 $1.00**  **$1.00**

4 SEALING COMPOUND, POSITION SENSOR 060701-N0502-112 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

5 WIPER CONTACT, POSITION SENSOR 060701-N0502-113 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

6 CONNECTOR HARDWARE, POSITION

SENSOR 060701-N0502-114 **1** S **$0.00** $0.15 **$0.00 $0.15**  **$0.15**

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

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

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

**Material**

**$1.47** 

### "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.

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$5.31**

**T1 or OEM Total Manufacturing Cost: $1.47**  **$1.06 $2.41**  **$4.94 $0.01**  **$0.22 $0.14**  **$0.00 $0.37**  **$5.31**

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

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

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

----- ----- ----- **$0.03 $0.35**  **$0.32 $0.13**  **$0.82**

**Base Cost Impact to Vehicle: $1.47**  **$1.06 $2.41**  **$4.94 $0.04**  **$0.56 $0.46**  **$0.13 $1.20**  **$6.14 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $6.14** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **3 1** 



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



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-POSITION SENSOR, FRONT SHELL 060701-N0502-102

SHAFT and CARRIER ASM 060701-N0502-131

CARRIER, WIPER CONTACT 060701-N0502-104

SHAFT ASM w CAP 060701-N0502-105

SHAFT, POSITION SENSOR 060701-N0502-106

HOUSING, POSITION SENSOR 060701-N0502-107

CAP, POSITION SENSOR 060701-N0502-108

SHAFT RETAINER, MOLDED - POSITION

SENSOR 060701-N0502-109 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.60 $1.67**  **$2.27 $0.01**  **$0.14 $0.09**  **$0.00 $0.23**  Place board, spring and shaft asm in housing.Insert molded retainer and solder connections.Apply base to housing with adhesive and sealant. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 60 **1.0 2.0** 

**$0.20 $0.56**  **$0.76 $0.00**  **$0.05 $0.03**  **$0.00 $0.08**  Assemble molded cap and base to shaft. Place wiper contact onto retainer and secure with clip. Place onto

shaft base. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 20 **1.0 1.0** 

**$0.02 $0.01**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 10 20 **1.0 1.0** 

**$0.02 $0.01**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton, 10 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 10 20 **1.0 1.0** 

**$0.13 $0.14**  **$0.29 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 25 **1.0 1.0** 

**$0.03 $0.01**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  55-150 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 4 12 **1.0 1.0** 

**$0.02 $0.01**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 4 8 **1.0 1.0** 

**$0.02 $0.01**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 4 8 **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

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

SPRING, POSITION SENSOR 060701-N0502-110 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Insert valve, apply adhesive and press base to cover **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** 20 2 1 20 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  55-150 ton, 10 cavity mold **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** 2 1 10 20 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** 2 1 10 20 **1.0 1.0** 

**$0.00**

**$0.05**



### 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 6 

# 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.

BOARD, POSITION SENSOR 060701-N0502-111

SEALING COMPOUND, POSITION SENSOR 060701-N0502-112

WIPER CONTACT, POSITION SENSOR 060701-N0502-113

CONNECTOR HARDWARE, POSITION

SENSOR 060701-N0502-114 

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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

**$1.00**

**$0.03**

**$0.10**

**$0.15**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$1.06 $2.41**  **$4.94 $0.01**  **$0.22 $0.14**  **$0.00 $0.37** 

**2**
**$5.31**



### 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: 5 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

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

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

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

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

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

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

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

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

-



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

H-POSITION SENSOR, FRONT SHELL 060701-N0502-102

SHAFT and CARRIER ASM 060701-N0502-131

CARRIER, WIPER CONTACT 060701-N0502-104

SHAFT ASM w CAP 060701-N0502-105

SHAFT, POSITION SENSOR 060701-N0502-106

HOUSING, POSITION SENSOR 060701-N0502-107

CAP, POSITION SENSOR 060701-N0502-108

SHAFT RETAINER, MOLDED - POSITION

SENSOR 060701-N0502-109 **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

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

-

**120 30.00**  2.00

**180 20.00**  1.00

**1800 2.00**  1.00

**1800 2.00**  1.00

**144 25.00**  0.50

**1200 3.00**  1.00

**1800 2.00**  1.00

**1800 2.00**  1.00

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

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

-



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

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

SPRING, POSITION SENSOR 060701-N0502-110 **180 20.00**  0.25

**1800 2.00**  1.00

**1800 2.00**  1.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# 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.

BOARD, POSITION SENSOR 060701-N0502-111

SEALING COMPOUND, POSITION SENSOR 060701-N0502-112

WIPER CONTACT, POSITION SENSOR 060701-N0502-113

CONNECTOR HARDWARE, POSITION

SENSOR 060701-N0502-114**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 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

**Burden**

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

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

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

### End

**Item Scrap** 

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

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

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

**R&D**

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

**Mark**

**up Rate**  **Total**

**Mark**

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

### Material

A 

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

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

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

3 H Brake Booster Assembly, Populated 060701-N0502-01 **1** ASSEMBLE T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **124 2**  **2 1**  0.000 **$0.05 $38.55**  **$15.00 $30.00**  **$0.00 $0.62**  **$0.24 $0.86**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.86 $0.86**  **$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** 

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



### 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**



### 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**



### D 

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

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

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

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

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

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

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

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

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

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

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

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

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

**Material**

**$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



### 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 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.86**

**T1 or OEM Total Manufacturing Cost: $0.00**  **$0.62 $0.24**  **$0.86 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.86**

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

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

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

----- ----- ----- **$0.00 $0.06**  **$0.05 $0.02**  **$0.13**

**Base Cost Impact to Vehicle: $0.00**  **$0.62 $0.24**  **$0.86 $0.00**  **$0.06 $0.05**  **$0.02 $0.13**  **$1.00 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.00**  **3 1** 



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

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H Brake Booster Assembly, Populated 060701-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** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.62 $0.24**  **$0.86 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Two operator, Two station.Mate brake booster asm to master cylinder with two nuts and apply paint marker. Push vacuum hose booster in place. Position clamp and apply paint marker **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 58.0 1 1 58.0 **1.0 2.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

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

**Total**

**$0.62 $0.24**  **$0.86 $0.00**  **$0.00 $0.00**  **$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: 4 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

**$0.86 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: 5 of 6 

# 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)

H Brake Booster Assembly, Populated 060701-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** 

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

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

-

**124 29.00**  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)

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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

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

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

-
**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

**Burden**

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

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

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

### End

**Item Scrap** 

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

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

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

**R&D**

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

**Mark**

**up Rate**  **Total**

**Mark**

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

### Material

A 

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

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

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

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

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

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

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

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** 

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



### 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**



### C 

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

1 ASSEMBLE **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **180 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.08 $0.14**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.15 $0.15**  **$0.00**

2 H-VACUUM HOSE FITTING, FRONT SHELL -

BASE **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.015 **$1.74 $41.48**  **$16.39 $16.39**  **$0.03 $0.02**  **$0.01 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.06 $0.06**  **$0.03**

3 H-VACUUM HOSE FITTING, FRONT SHELL -

COVER **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1800 1**  **1 1**  0.015 **$1.74 $41.48**  **$16.39 $16.39**  **$0.03 $0.02**  **$0.01 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.06 $0.06**  **$0.03**



### D 

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

**Account Purchase** 

**Price/ Purchase** 

**Price Net, Purchase** 

**Price Net,** 

### D 

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

**Cost Unit**  **PIA End Item** 

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

2 VALVE **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

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

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

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

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

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

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

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

### "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



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material**

**$0.10**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.33**

**T1 or OEM Total Manufacturing Cost: $0.10**  **$0.10 $0.10**  **$0.30 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  **$0.33**

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

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

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

----- ----- ----- **$0.00 $0.02**  **$0.02 $0.01**  **$0.05**

**Base Cost Impact to Vehicle: $0.10**  **$0.10 $0.10**  **$0.30 $0.00**  **$0.04 $0.03**  **$0.01 $0.08**  **$0.38 $0**  **$0**

**Packaging Cost: $0.00** 

**3 1** 



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

**Net Cost Impact to Vehicle: $0.38** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

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

ASSEMBLE

H-VACUUM HOSE FITTING, FRONT SHELL -

BASE

H-VACUUM HOSE FITTING, FRONT SHELL -

COVER



## 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** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.05 $0.08**  **$0.14 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  Insert valve, apply adhesive and press base to cover **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 20 2 1 20 **1.0 1.0** 

**$0.02 $0.01**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  55-150 ton, 10 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2 1 10 20 **1.0 1.0** 

**$0.02 $0.01**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  55-150 ton , 10 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2 1 10 20 **1.0 1.0** 



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

VALVE **$0.00**

**$0.05**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$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: 4 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

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

**Total**

**$0.10 $0.10**  **$0.30 $0.00**  **$0.02 $0.01**  **$0.00 $0.03** 

**$0.33 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: 5 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

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

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

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

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

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

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

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

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

-



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

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

ASSEMBLE

H-VACUUM HOSE FITTING, FRONT SHELL -

BASE

H-VACUUM HOSE FITTING, FRONT SHELL -

COVER



## 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!** 

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

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

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

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

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

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

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

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

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

-

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

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

-

**180 20.00**  0.25

**1800 2.00**  1.00

**1800 2.00**  1.00



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

VALVE



### 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 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

**Burden**

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

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

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

### End

**Item Scrap** 

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

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

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

**R&D**

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

**Mark**

**up Rate**  **Total**

**Mark**

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

### Material

A 

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

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

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

3 H Brake Booster Assembly(Master Cylinder Removed) 060701-N0502-02 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **157 3**  **3 1**  0.000 **$0.05 $38.55**  **$15.00 $45.00**  **$0.00 $0.74**  **$0.29 $1.03**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.03 $1.03**  **$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**

**0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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)**

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**



### 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**



### 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**



### D 

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

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

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

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

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

2 H-SPRING, LARGE BRAKE BOOSTER 060701-N0502-04 **1** S **$0.00** $0.23 **$0.00 $0.23**  **$0.23**

3 H-LABEL, BRAKE BOOSTER, FRONT SHELL 060701-N0502-05 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

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

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

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

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

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

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

**Material**

**$0.33** 

### "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



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.36**

**T1 or OEM Total Manufacturing Cost: $0.33**  **$0.74 $0.29**  **$1.36 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.36**

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

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

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

----- ----- ----- **$0.01 $0.09**  **$0.08 $0.03**  **$0.21**

**Base Cost Impact to Vehicle: $0.33**  **$0.74 $0.29**  **$1.36 $0.01**  **$0.09 $0.08**  **$0.03 $0.21**  **$1.57 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.57**  **3 1** 



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

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H Brake Booster Assembly(Master Cylinder

Removed) 060701-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** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.74 $0.29**  **$1.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Three operator, Three station. Apply label and insert electrical connector into large shell. Insert large spring and mate with rear shell - crimp tabs **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 69.0 5 1 69.0 **1.0 3.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

### 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)

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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

H-SPRING, LARGE BRAKE BOOSTER 060701-N0502-04

H-LABEL, BRAKE BOOSTER, FRONT SHELL 060701-N0502-05 **$0.23**

**$0.10**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.74 $0.29**  **$1.36 $0.00**  **$0.00 $0.00**  **$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: 4 of 6 

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

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T** 

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

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

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

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

### 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**

**$1.36 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: 5 of 6 

# 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)

H Brake Booster Assembly(Master Cylinder

Removed) 060701-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** 

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

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

-

**157 23.00**  3.00

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

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

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

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

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

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



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

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

**Purchase Part - Commodity ( Value taken from Purchase Part Database)** -
**#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

-

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

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

-

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

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

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

-

H-SPRING, LARGE BRAKE BOOSTER 060701-N0502-04

H-LABEL, BRAKE BOOSTER, FRONT SHELL 060701-N0502-05



### 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 6 

# 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 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

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


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

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

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 H-REAR SHELL W/PLATES 060701-N0502-06 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **132 6**  **6 1**  0.000 **$0.05 $38.55**  **$15.00 $90.00**  **$0.00 $1.76**  **$0.68 $2.44**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$2.44 $2.44**  **$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** 

### 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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-EXCLUDER 060701-N0502-07 **1** Mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1125 1**  **1 1**  0.047 **$1.04 $41.48**  **$16.39 $16.39**  **$0.05 $0.04**  **$0.01 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.05**

2 H - VACUUM SEAL, REAR SHELL 060701-N0502-08 **1** Mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1500 1**  **1 1**  0.0190 **$0.99 $41.48**  **$16.39 $16.39**  **$0.02 $0.03**  **$0.01 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.06 $0.06**  **$0.02**



### 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**



### 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 H-FOAM GASKET, REAR 060701-N0502-09 **1** S **$0.00** $0.08 **$0.00 $0.08**  **$0.08**

2 H-TINNERMAN NUT 060701-N0502-10 **4** S **$0.00** $0.01 **$0.00 $0.04**  **$0.04**

3 H FOAM SEAL, REAR SHELL 060701-N0502-11 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

4 H-FOAM FILTER 060701-N0502-12 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

5 H-HOSE CLAMP, EXCLUDER 060701-N0502-13 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

6 H-LOCK NUT, CLEVIS TO SHAFT 060701-N0502-14 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

7 H- SCREW, SOLENOID TO SHAFT 060701-N0502-15 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

8 **0 $0.00**  **$0.00 $0.00**  **$0.00**

**Material**

**$0.52** 

### "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.



### 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 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$3.06**

**T1 or OEM Total Manufacturing Cost: $0.52**  **$1.82 $0.71**  **$3.05 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  **$3.06**

**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**

----- ----- ----- **$0.02 $0.20**  **$0.18 $0.08**  **$0.47**

**Base Cost Impact to Vehicle: $0.52**  **$1.82 $0.71**  **$3.05 $0.02**  **$0.21 $0.19**  **$0.08 $0.49**  **$3.54 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $3.54**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-REAR SHELL W/PLATES 060701-N0502-06



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$1.76 $0.68**  **$2.44 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Six Operator, Six station - Push vacuum seal onto rear shell and apply foam gasket on it. Apply stud plate and fasten to rear shell with four tinnerman nuts.Place center section booster assembly in rear shell and place reaction disk/output shaft assembly into it.Place foam filter over output shaft Attach clevis to output shaft with lock nut. Place excluder over it and secure to stud plate with hose clamp.Screw solenoid to output shaft. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 164.0 14 1 164.0 **1.0 6.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-EXCLUDER 060701-N0502-07

H - VACUUM SEAL, REAR SHELL 060701-N0502-08



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.04 $0.01**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 3.20 1 10 32.00 **1.0 1.0** 

**$0.03 $0.01**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2.40 1 10 24.00 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

H-FOAM GASKET, REAR 060701-N0502-09

H-TINNERMAN NUT 060701-N0502-10

H FOAM SEAL, REAR SHELL 060701-N0502-11

H-FOAM FILTER 060701-N0502-12

H-HOSE CLAMP, EXCLUDER 060701-N0502-13

H-LOCK NUT, CLEVIS TO SHAFT 060701-N0502-14

H- SCREW, SOLENOID TO SHAFT 060701-N0502-15 **$0.08**

**$0.04**

**$0.06**

**$0.06**

**$0.10**

**$0.05**

**$0.06**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$1.82 $0.71**  **$3.05 $0.00**  **$0.01 $0.01**  **$0.00 $0.02** 



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**$3.06 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: 5 of 6 

# 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)

H-REAR SHELL W/PLATES 060701-N0502-06



### 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!** 

-

**132 27.33**  6.00

**#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)

H-EXCLUDER 060701-N0502-07

H - VACUUM SEAL, REAR SHELL 060701-N0502-08



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**1125 3.20**  1.00

**1500 2.40**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H-FOAM GASKET, REAR 060701-N0502-09

H-TINNERMAN NUT 060701-N0502-10

H FOAM SEAL, REAR SHELL 060701-N0502-11

H-FOAM FILTER 060701-N0502-12

H-HOSE CLAMP, EXCLUDER 060701-N0502-13

H-LOCK NUT, CLEVIS TO SHAFT 060701-N0502-14

H- SCREW, SOLENOID TO SHAFT 060701-N0502-15



### 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 6 

# 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 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 0.5**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 H-REAR SHELL,PAINTED 060701-N0502-16 **1** Paint T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.03**  **$0.05 $0.09**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.09 $0.09**  **$0.00**

5 H-REAR SHELL,PRESSED 060701-N0502-16A **1** Press T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **206 0.5**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.09**  **$0.15 $0.24**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.24 $0.24**  **$0.00**

6 H-REAR SHELL,WASHED 060701-N0502-17 **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $0.11**  **$0.00**

7 H-REAR SHELL,STAMPED 060701-N0502-17A **1** Stamp T1 Assembly, Mark-up Applied LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS **480 0.5**  **1 1**  3.070 **$0.45 $42.73**  **$141.76 $141.76**  **$1.38 $0.04**  **$0.30 $1.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.72 $1.72**  **$1.38** 

### 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 H-REAR SHELL,STAMPED 060701-N0502-17A **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS **480 0.5**  **1 1**  3.070 **$0.45 $42.73**  **$141.76 $141.76**  **$1.38 $0.04**  **$0.30 $1.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.72 $1.72**  **$1.38**

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**



### 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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 H-STUD, REAR SHELL 060701-N0502-18 **4** S **$0.00** $0.06 **$0.00 $0.24**  **$0.24**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$1.62**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$2.40**

**T1 or OEM Total Manufacturing Cost: $1.62**  **$0.21 $0.57**  **$2.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$2.40** 

### "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

**3 1** 



### 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: 2 of 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.16**  **$0.14 $0.06**  **$0.37**

**Base Cost Impact to Vehicle: $1.62**  **$0.21 $0.57**  **$2.40 $0.01**  **$0.16 $0.14**  **$0.06 $0.37**  **$2.77 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.77** **C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) 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** **)** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) **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 Cost Total: **$0.000** 

### Part Size: Parts/Layer: Number of Layers: Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-REAR SHELL,PAINTED 060701-N0502-16

H-REAR SHELL,PRESSED 060701-N0502-16A

H-REAR SHELL,WASHED 060701-N0502-17

H-REAR SHELL,STAMPED 060701-N0502-17A



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **1 1**  **10 10**  **47 470**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 0.5** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.03 $0.05**  **$0.09 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Spray Paint **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.09 $0.15**  **$0.24 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Press Rear Shell and studs together **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 35 1 1 35 **1.0 2.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.04 $0.30**  **$1.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 7.5 1 1 7.5 **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**

H-REAR SHELL,STAMPED 060701-N0502-17A



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.04**  **$0.30 $1.72**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** 1000 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 7.5 1 1 7.5 **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!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

H-STUD, REAR SHELL 060701-N0502-18 **$0.24**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.21 $0.57**  **$2.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$2.40 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**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: 5 of 6 

# 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)

H-REAR SHELL,PAINTED 060701-N0502-16

H-REAR SHELL,PRESSED 060701-N0502-16A

H-REAR SHELL,WASHED 060701-N0502-17

H-REAR SHELL,STAMPED 060701-N0502-17A



### 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!** 

-

**277 13.00**  0.25

**206 17.50**  0.50

**277 13.00**  0.25

**480 7.50**  0.50 H-REAR SHELL,STAMPED 060701-N0502-17A



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 480**  **7.50** 0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H-STUD, REAR SHELL 060701-N0502-18



### 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 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 H-STUD PLATE, REAR SHELL 060701-N0502-19 **1** Electroplate T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Plate/Finish, SMS, MHC **184 0.25**  **0.5 1**  0.000 **$0.00 $40.84**  **$125.00 $62.50**  **$0.00 $0.06**  **$0.34 $0.40**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.40 $0.40**  **$0.00**

3 H-STUD PLATE, REAR SHELL 060701-N0502-19A **1** Weld T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, LC **133 0.25**  **1 1**  0.000 **$0.00 $41.55**  **$100.00 $100.00**  **$0.00 $0.08**  **$0.75 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00**

4 H-STUD PLATE, REAR SHELL 060701-N0502-19B **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $0.11**  **$0.00**

3 H-STUD PLATE, REAR SHELL 060701-N0502-19C **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS **5143 0.5**  **1 1**  0.192 **$0.45 $42.73**  **$24.60 $24.60**  **$0.09 $0.00**  **$0.00 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.09**

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** 

### 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)**

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**



### 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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 H-STUD PLATE WASHER, REAR SHELL 060701-N0502-20 **4** S **$0.00** $0.0075 **$0.00 $0.03**  **$0.03**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.12**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.46** 

### "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

**1**



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**T1 or OEM Total Manufacturing Cost: $0.12**  **$0.17 $1.17**  **$1.46 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.46**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.09**  **$0.09 $0.04**  **$0.23**

**Base Cost Impact to Vehicle: $0.12**  **$0.17 $1.17**  **$1.46 $0.01**  **$0.09 $0.09**  **$0.04 $0.23**  **$1.69 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.69** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******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****** 

### PACKAGING CALCULATIONS: **3** 

### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm)

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-STUD PLATE, REAR SHELL 060701-N0502-19

H-STUD PLATE, REAR SHELL 060701-N0502-19A

H-STUD PLATE, REAR SHELL 060701-N0502-19B

H-STUD PLATE, REAR SHELL 060701-N0502-19C



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.06 $0.34**  **$0.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

Zinc Plating, Batched Processed **1 1**  **10 10**  **47 470**  **957 3.76**  **85% 1126**  **3.20** 9.8 1 1 9.8 **1.0 0.5** 

**$0.08 $0.75**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Weld washers to stud plate **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 27 4 1 27 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

In line Washer Turbo Tunnel **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**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

H-STUD PLATE WASHER, REAR SHELL 060701-N0502-20 **$0.00**

**$0.03**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.17 $1.17**  **$1.46 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.46 2** 



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**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: 5 of 6 

# 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)

H-STUD PLATE, REAR SHELL 060701-N0502-19

H-STUD PLATE, REAR SHELL 060701-N0502-19A

H-STUD PLATE, REAR SHELL 060701-N0502-19B

H-STUD PLATE, REAR SHELL 060701-N0502-19C



### 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!** 

-

**184 19.60**  0.25

**133 27.00**  0.25

**277 13.00**  0.25

**5143 0.70**  0.50

**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H-STUD PLATE WASHER, REAR SHELL 060701-N0502-20



### 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 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 H-CLEVIS TO PEDAL 060701-N0502-21 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **182 0.25**  **1 1**  0.000 **$0.05 $38.55**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.08 $0.14**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.14 $0.14**  **$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** 

### 9,574

**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)**

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-BUMPER, CLEVIS TO PEDAL 060701-N0502-22 **2** Mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **750 1**  **1 1**  0.002 **$1.04 $41.48**  **$16.39 $16.39**  **$0.00 $0.06**  **$0.02 $0.08**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.09 $0.17**  **$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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  **$0.00 $0.00**  **$0.00**

**Material** 

### "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



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**$0.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.17**

**T1 or OEM Total Manufacturing Cost: $0.00**  **$0.16 $0.13**  **$0.29 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  **$0.31**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.02**  **$0.02 $0.01**  **$0.05**

**Base Cost Impact to Vehicle: $0.00**  **$0.16 $0.13**  **$0.29 $0.00**  **$0.03 $0.02**  **$0.01 $0.06**  **$0.36 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.36**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-CLEVIS TO PEDAL 060701-N0502-21



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.05 $0.08**  **$0.14 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Insert bumpers into overmold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19.8 1 1 19.8 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-BUMPER, CLEVIS TO PEDAL 060701-N0502-22



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.11 $0.04**  **$0.16 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 4.8 1 10 48 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **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**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**$0.16 $0.13**  **$0.29 $0.00**  **$0.01 $0.01**  **$0.00 $0.02** 

**$0.31 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: 5 of 6 

# 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)

H-CLEVIS TO PEDAL 060701-N0502-21



### 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!** 

-

**182 19.80**  0.25

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-BUMPER, CLEVIS TO PEDAL 060701-N0502-22



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**750 4.80**  1.00

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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** 

### 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** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**



### 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 H-CLEVIS TO PEDAL 060701-N0502-23 **1** Electroplate T2/T3 Plate/Finish Mech.,

SSLC Not Applicable Plating/Coating Operator Plate/Finish, SMS, MHC **184 0.25**  **0.5 1**  0.000 **$0.00 $40.84**  **$125.00 $62.50**  **$0.00 $0.06**  **$0.34 $0.40**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.44 $0.44**  **$0.00**

3 H-CLEVIS TO PEDAL 060701-N0502-23A **1** Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.12 $0.12**  **$0.00**

4 H-CLEVIS TO PEDAL 060701-N0502-23B **1** Weld T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **277 0.25**  **1 1**  0.000 **$0.00 $41.55**  **$100.00 $100.00**  **$0.00 $0.04**  **$0.36 $0.40**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.44 $0.44**  **$0.00**

5 H-SUPPORT,CLEVIS TO PEDAL 060701-N0502-24 **1** Stamp T2/T3 Stamp/Form, MSMC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.065 **$0.45 $42.73**  **$15.50 $15.50**  **$0.03 $0.00**  **$0.00 $0.04**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.00**  **$0.04 $0.04**  **$0.03**

6 H-CLEVIS TO PEDAL,STAMPED 060701-N0502-25 **1** Stamp T2/T3 Stamp/Form, MSMC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS **2118 0.5**  **1 1**  0.465 **$0.45 $42.73**  **$24.60 $24.60**  **$0.21 $0.01**  **$0.01 $0.23**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.03**  **$0.26 $0.26**  **$0.21**

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**



### 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**

**Supplier Purchase**  **Purchase Purchase**  

### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  **$0.00 $0.00**  **$0.00** 

### "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



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material**

**$0.24**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.30**

**T1 or OEM Total Manufacturing Cost: $0.24**  **$0.14 $0.79**  **$1.17 $0.00**  **$0.07 $0.05**  **$0.00 $0.13**  **$1.30**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.08**  **$0.08 $0.03**  **$0.20**

**Base Cost Impact to Vehicle: $0.24**  **$0.14 $0.79**  **$1.17 $0.01**  **$0.16 $0.13**  **$0.04 $0.33**  **$1.50 $0**  **$0**

**Packaging Cost: $0.00** 

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**Net Cost Impact to Vehicle: $1.50** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-CLEVIS TO PEDAL 060701-N0502-23

H-CLEVIS TO PEDAL 060701-N0502-23A

H-CLEVIS TO PEDAL 060701-N0502-23B

H-SUPPORT,CLEVIS TO PEDAL 060701-N0502-24

H-CLEVIS TO PEDAL,STAMPED 060701-N0502-25



## 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** 

**$0.06 $0.34**  **$0.40 $0.00**  **$0.02 $0.02**  **$0.00 $0.04** 

Zinc Plating, Batched Processed **1 1**  **10 10**  **47 470**  **957 3.76**  **85% 1126**  **3.20** 9.8 1 1 9.8 **1.0 0.5** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.01 $0.00**  **$0.00 $0.01** 

In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.04 $0.36**  **$0.40 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  Laer Weld **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 2 1 13 **1.0 1.0** 

**$0.00 $0.00**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.6 1 1 0.6 **1.0 1.0** 

**$0.01 $0.01**  **$0.23 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  200 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.7 1 1 1.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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**

**$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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.14 $0.79**  **$1.17 $0.00**  **$0.07 $0.05**  **$0.00 $0.13** 

**$1.30 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: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-CLEVIS TO PEDAL 060701-N0502-23

H-CLEVIS TO PEDAL 060701-N0502-23A

H-CLEVIS TO PEDAL 060701-N0502-23B

H-SUPPORT,CLEVIS TO PEDAL 060701-N0502-24

H-CLEVIS TO PEDAL,STAMPED 060701-N0502-25



## 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!** 

-

**184 19.60**  0.25

**277 13.00**  0.25

**277 13.00**  0.25

**6000 0.60**  0.50

**2118 1.70**  0.50

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database)

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 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 H-CENTER SECTION, BOOSTER 060701-N0502-26 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **129 1**  **1 1**  0.000 **$0.05 $38.55**  **$15.00 $15.00**  **$0.00 $0.30**  **$0.12 $0.41**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.41 $0.41**  **$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** 

### 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)**

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-BUMPER, CLEVIS TO PEDAL 060701-N0502-27 **2** Mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **750 1**  **1 1**  0.002 **$1.04 $41.48**  **$16.39 $16.39**  **$0.00 $0.06**  **$0.02 $0.08**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.09 $0.17**  **$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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  **$0.00 $0.00**  **$0.00**

**Material** 

### "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



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**$0.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.17**

**T1 or OEM Total Manufacturing Cost: $0.00**  **$0.41 $0.16**  **$0.57 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  **$0.59**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.04**  **$0.04 $0.01**  **$0.09**

**Base Cost Impact to Vehicle: $0.00**  **$0.41 $0.16**  **$0.57 $0.00**  **$0.05 $0.04**  **$0.01 $0.11**  **$0.68 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.68**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-CENTER SECTION, BOOSTER 060701-N0502-26



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.30 $0.12**  **$0.41 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Push input rod connector in place, inser input rod and secure with key booster clip **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 27.9 3 1 27.9 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-BUMPER, CLEVIS TO PEDAL 060701-N0502-27



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.11 $0.04**  **$0.16 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 4.8 1 10 48 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **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**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**$0.41 $0.16**  **$0.57 $0.00**  **$0.01 $0.01**  **$0.00 $0.02** 

**$0.59 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: 5 of 6 

# 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)

H-CENTER SECTION, BOOSTER 060701-N0502-26



### 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!** 

-

**129 27.90**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-BUMPER, CLEVIS TO PEDAL 060701-N0502-27



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**750 4.80**  1.00

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 H-PLATES AND DIAPHRAGMS 060701-N0502-28 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **267 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.04**  **$0.06 $0.09**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.09 $0.09**  **$0.00**

2 H-FRONT PLATE 060701-N0502-29A **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $0.11**  **$0.00**

3 H-FRONT PLATE 060701-N0502-29B **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS **2118 0.5**  **1 1**  1.170 **$0.45 $42.73**  **$24.60 $24.60**  **$0.53 $0.01**  **$0.01 $0.55**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.55 $0.55**  **$0.53**

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** 

### 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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-CENTER DIAPHRAGM,MOLDED 060701-N0502-29C **1** Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, MLS **837 1**  **1 1**  0.286 **$1.32 $41.48**  **$90.59 $90.59**  **$0.38 $0.05**  **$0.11 $0.54**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.59 $0.59**  **$0.38**

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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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**

**Material**

**$0.90**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.25**

**T1 or OEM Total Manufacturing Cost: $0.90**  **$0.13 $0.25**  **$1.29 $0.00**  **$0.03 $0.02**  **$0.00 $0.06**  **$1.34** 

### "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

**3 1** 



### 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: 2 of 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.09**  **$0.08 $0.03**  **$0.21**

**Base Cost Impact to Vehicle: $0.90**  **$0.13 $0.25**  **$1.29 $0.01**  **$0.12 $0.10**  **$0.03 $0.26**  **$1.55 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.55** **C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) 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** **)** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) **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 Cost Total: **$0.000** 

### Part Size: Parts/Layer: Number of Layers: Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-PLATES AND DIAPHRAGMS 060701-N0502-28

H-FRONT PLATE 060701-N0502-29A

H-FRONT PLATE 060701-N0502-29B



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.04 $0.06**  **$0.09 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Press Center diaphram onto plate and insert Valve body **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 27 4 2 27 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.01 $0.01**  **$0.55 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  200 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.7 1 1 1.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-CENTER DIAPHRAGM,MOLDED 060701-N0502-29C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.05 $0.11**  **$0.54 $0.00**  **$0.03 $0.02**  **$0.00 $0.06**  4 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4.30 1 4 17.20 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.13 $0.25**  **$1.29 $0.00**  **$0.03 $0.02**  **$0.00 $0.06** 

**$1.34 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**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: 5 of 6 

# 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)

H-PLATES AND DIAPHRAGMS 060701-N0502-28

H-FRONT PLATE 060701-N0502-29A

H-FRONT PLATE 060701-N0502-29B



### 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** 

**267 13.50**  0.25

**277 13.00**  0.25

**2118 1.70**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-CENTER DIAPHRAGM,MOLDED 060701-N0502-29C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**837 4.30**  1.00

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 H-VALVE BODY W SEAL 060701-N0502-30 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **133 0.25**  **1 1**  **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.07**  **$0.11 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $0.18**  **$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** 

### 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)**

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-VALVE BODY,MOLDED 060701-N0502-31 **1** Mold T2/T3 Inject. Mold, SSLC PET-GF36 Mold/Cast/Sinter Operator Inject. Mold, MLS **825 1**  **1 1**  0.207 **$1.20 $41.48**  **$90.59 $90.59**  **$0.25 $0.05**  **$0.11 $0.41**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.45 $0.45**  **$0.25**

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**



### 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**



### 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 H - VALVE BODY SQ CUT, MOLDED 060701-N0502-32 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

2 H- STAR W ASHER, VALVE BODY 060701-N0502-33 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material** 

### "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

**$0.32**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.70**

**T1 or OEM Total Manufacturing Cost: $0.32**  **$0.12 $0.22**  **$0.66 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  **$0.70**

**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**

----- ----- ----- **$0.00 $0.05**  **$0.04 $0.02**  **$0.11**

**Base Cost Impact to Vehicle: $0.32**  **$0.12 $0.22**  **$0.66 $0.00**  **$0.07 $0.06**  **$0.02 $0.15**  **$0.81 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.81**  **3 1** 



### 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: 2 of 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447**  

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base

**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 Cost Total: **$0.000** 

### 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 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: 3 of 6 

# 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)

H-VALVE BODY W SEAL 060701-N0502-30



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.07 $0.11**  **$0.18 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  One operator, One station. Lubricate inner valve body and apply seal and washer. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 27 1 1 27 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-VALVE BODY,MOLDED 060701-N0502-31



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H - VALVE BODY SQ CUT, MOLDED 060701-N0502-32

H- STAR W ASHER, VALVE BODY 060701-N0502-33 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.05 $0.11**  **$0.41 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  4 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4.4 1 4 17.45 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.06**

**$0.01**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total Labor**  **Burden TMC**  **Scrape SG&A**  **Profit ED&T**  **Total**

**$0.12 $0.22**  **$0.66 $0.00**  **$0.02 $0.02**  **$0.00 $0.04** 

**$0.70 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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: 5 of 6 

# 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)

H-VALVE BODY W SEAL 060701-N0502-30



### 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!** 

-

**133 27.00**  0.25

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-VALVE BODY,MOLDED 060701-N0502-31



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H - VALVE BODY SQ CUT, MOLDED 060701-N0502-32

H- STAR W ASHER, VALVE BODY 060701-N0502-33 **#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**825 4.36**  1.00

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 H-REAR PLATE, DIA. CUP 060701-N0502-34 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **116 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.08**  **$0.13 $0.21**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.21 $0.21**  **$0.00**

2 H-REAR PLATE, CENTER SECTION 060701-N0502-35 **1** Wash T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil General Assembly Washing Equipment, LMC **240 0.25**  **1 1**  0.000 **$0.45 $38.55**  **$20.81 $20.81**  **$0.00 $0.04**  **$0.09 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.00**

3 H-REAR PLATE, CENTER SECTION 060701-N0502-35A **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS **2118 0.5**  **1 1**  0.983 **$0.45 $42.73**  **$24.60 $24.60**  **$0.44 $0.01**  **$0.01 $0.46**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.46 $0.46**  **$0.44**

4 H-REAR CUP, CENTER SECTION 060701-N0502-36 **1** Wash T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.45 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $0.11**  **$0.00**

5 H-REAR CUP, CENTER SECTION 060701-N0502-36A **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS **2118 0.5**  **1 1**  0.376 **$0.45 $42.73**  **$24.60 $24.60**  **$0.17 $0.01**  **$0.01 $0.19**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.19 $0.19**  **$0.17** 

### 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)**

H-REAR CUP, CENTER SECTION @ Bottom.

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-REAR DIAPHRAGM,MOLDED 060701-N0502-37 **1** Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, MLS **837 1**  **1 1**  0.232 **$1.32 $41.48**  **$90.59 $90.59**  **$0.31 $0.05**  **$0.11 $0.46**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.51 $0.51**  **$0.31**

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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account Purchase** 

**Price/ Purchase** 

**Price Net, Purchase** 

**Price Net,** 

### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database)

**Cost Unit**  **PIA End Item** 

1 **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**

**Material**

**$0.92** 

### "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



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.10**

**T1 or OEM Total Manufacturing Cost: $0.92**  **$0.23 $0.42**  **$1.57 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  **$1.62**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.11**  **$0.10 $0.04**  **$0.25**

**Base Cost Impact to Vehicle: $0.92**  **$0.23 $0.42**  **$1.57 $0.01**  **$0.13 $0.12**  **$0.04 $0.30**  **$1.87 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.87**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-REAR PLATE, DIA. CUP 060701-N0502-34

H-REAR PLATE, CENTER SECTION 060701-N0502-35

H-REAR PLATE, CENTER SECTION 060701-N0502-35A

H-REAR CUP, CENTER SECTION 060701-N0502-36

H-REAR CUP, CENTER SECTION 060701-N0502-36A



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.08 $0.13**  **$0.21 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Press Diaphragm into plate, locate cup over tabs, insert and bend tabs **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 31 1 1 31 **1.0 1.0** 

**$0.04 $0.09**  **$0.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 15 1 1 15 **1.0 1.0** 

**$0.01 $0.01**  **$0.46 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  200 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.7 1 1 1.7 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.01 $0.01**  **$0.19 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  200 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.7 1 1 1.7 **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**

H-REAR CUP, CENTER SECTION



## Purchase Part - High Impact Item (Full Cost Mapping)

H-REAR DIAPHRAGM,MOLDED 060701-N0502-37



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.05 $0.11**  **$0.46 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  4 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4.30 1 4 17.20 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.23 $0.42**  **$1.57 $0.00**  **$0.03 $0.02**  **$0.00 $0.05** 



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**$1.62 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: 5 of 6 

# 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)

H-REAR PLATE, DIA. CUP 060701-N0502-34

H-REAR PLATE, CENTER SECTION 060701-N0502-35

H-REAR PLATE, CENTER SECTION 060701-N0502-35A

H-REAR CUP, CENTER SECTION 060701-N0502-36

H-REAR CUP, CENTER SECTION 060701-N0502-36A



### 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** 

**116 31.00**  0.25

**240 15.00**  0.25

**2118 1.70**  0.50

**277 13.00**  0.25

**2118 1.70**  0.50 H-REAR CUP, CENTER SECTION



## Purchase Part - High Impact Item (Full Cost Mapping)

H-REAR DIAPHRAGM,MOLDED 060701-N0502-37



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**837 4.30**  1.00

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database)

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 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 H-CENTER PLATE W SEAL 060701-N0502-38 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **189 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.08 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.00**

2 H-CENTER PLATE 060701-N0502-38A **1** Wash T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil General Assembly Washing Equipment, LMC **240 0.25**  **1 1**  0.000 **$0.45 $38.55**  **$20.81 $20.81**  **$0.00 $0.04**  **$0.09 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.00**

3 H-CENTER PLATE 060701-N0502-38B **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **2000 0.5**  **1 1**  1.617 **$0.45 $42.73**  **$42.91 $42.91**  **$0.73 $0.01**  **$0.02 $0.76**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.76 $0.76**  **$0.73**

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** 

### 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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H - SEAL, CENTER PLATE 060701-N0502-39 **1** Mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1125 1**  **1 1**  0.030 **$0.99 $41.48**  **$16.39 $16.39**  **$0.03 $0.04**  **$0.01 $0.08**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.09 $0.09**  **$0.03**

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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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**

**Material**

**$0.76**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.98**

**T1 or OEM Total Manufacturing Cost: $0.76**  **$0.14 $0.20**  **$1.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  **$1.11** 

### "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

**3 1** 



### 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: 2 of 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.07**  **$0.07 $0.03**  **$0.17**

**Base Cost Impact to Vehicle: $0.76**  **$0.14 $0.20**  **$1.10 $0.01**  **$0.08 $0.07**  **$0.03 $0.18**  **$1.28 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.28** **C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) 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** **)** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) **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 Cost Total: **$0.000** 

### Part Size: Parts/Layer: Number of Layers: Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-CENTER PLATE W SEAL 060701-N0502-38

H-CENTER PLATE 060701-N0502-38A

H-CENTER PLATE 060701-N0502-38B



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.05 $0.08**  **$0.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Insert seal into center plate **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19 1 1 19 **1.0 1.0** 

**$0.04 $0.09**  **$0.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 15 1 1 15 **1.0 1.0** 

**$0.01 $0.02**  **$0.76 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  300 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 1 1.8 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H - SEAL, CENTER PLATE 060701-N0502-39



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.04 $0.01**  **$0.08 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 3.20 1 10 32.00 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.14 $0.20**  **$1.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 

**$1.11 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**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: 5 of 6 

# 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)

H-CENTER PLATE W SEAL 060701-N0502-38

H-CENTER PLATE 060701-N0502-38A

H-CENTER PLATE 060701-N0502-38B



### 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** 

**189 19.00**  0.25

**240 15.00**  0.25

**2000 1.80**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H - SEAL, CENTER PLATE 060701-N0502-39



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**1125 3.20**  1.00

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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** 

### 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)**

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-CONNECTOR, INPUT ROD TO SOLENOID 060701-N0502-40 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **116 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.17**  **$0.13 $0.30**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.33 $0.33**  **$0.00**

2 H-HOUSING CONNECTER, SOLENOID 060701-N0502-41 **1** Mold T2/T3 Inject. Mold, SSLC PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1440 1**  **1 1**  0.016 **$6.02 $41.48**  **$16.39 $16.39**  **$0.10 $0.03**  **$0.01 $0.14**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.15 $0.15**  **$0.10**

3 H-RETAINER CONNECTER 060701-N0502-42 **1** Mold T2/T3 Inject. Mold, SSLC PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **4000 1**  **1 1**  0.003 **$6.02 $41.48**  **$16.39 $16.39**  **$0.02 $0.01**  **$0.00 $0.03**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04**  **$0.02**



### 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**



### 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 H-SEAL CONNECTER, SOLENOID 060701-N0502-43 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

2 H-W AVE W ASHER, CONNECTER 060701-N0502-44 **1** S **$0.00** $0.09 **$0.00 $0.09**  **$0.09**

3 H- W ASHER, CONNECTER 060701-N0502-45 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.27**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.67** 

### "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

**1**

**T1 or OEM Total Manufacturing Cost: $0.27**  **$0.21 $0.14**  **$0.62 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  **$0.67**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.04**  **$0.04 $0.02**  **$0.10**

**Base Cost Impact to Vehicle: $0.27**  **$0.21 $0.14**  **$0.62 $0.00**  **$0.07 $0.06**  **$0.02 $0.15**  **$0.78 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.78**  **3** 

### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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:
Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Apply seal to connector housing. Inser washers and snap on retainer **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-CONNECTOR, INPUT ROD TO SOLENOID 060701-N0502-40

H-HOUSING CONNECTER, SOLENOID 060701-N0502-41

H-RETAINER CONNECTER 060701-N0502-42 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H-SEAL CONNECTER, SOLENOID 060701-N0502-43

H-W AVE W ASHER, CONNECTER 060701-N0502-44

H- W ASHER, CONNECTER 060701-N0502-45 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.17 $0.13**  **$0.30 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Apply seal to connector housing. Inser washers and snap on retainer **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 31 4 1 31 **1.0 1.0** 

**$0.03 $0.01**  **$0.14 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  4 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2.5 1 4 10 **1.0 1.0** 

**$0.01 $0.00**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.9 1 10 9 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.06**

**$0.09**

**$0.01**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.21 $0.14**  **$0.62 $0.00**  **$0.03 $0.02**  **$0.00 $0.05** 

**$0.67 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-CONNECTOR, INPUT ROD TO SOLENOID 060701-N0502-40

H-HOUSING CONNECTER, SOLENOID 060701-N0502-41

H-RETAINER CONNECTER 060701-N0502-42 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H-SEAL CONNECTER, SOLENOID 060701-N0502-43

H-W AVE W ASHER, CONNECTER 060701-N0502-44

H- W ASHER, CONNECTER 060701-N0502-45 **#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**116 31.00**  0.50

**1440 2.50**  1.00

**4000 0.90**  1.00

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 H-INPUT ROD ASSEMBLY 060701-N0502-46 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **131 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.29**  **$0.23 $0.52**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.52 $0.52**  **$0.00**

4 H-INPUT ROD, VALVE BODY 060701-N0502-46A **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.00**

5 H-INPUT ROD, VALVE BODY 060701-N0502-46B **1** Machine T1 Assembly, Mark-up Applied @ Bottom. MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA **195 1**  **2 1**  0.150 **$0.74 $36.98**  **$20.48 $40.96**  **$0.11 $0.19**  **$0.21 $0.51**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.51 $0.51**  **$0.11**

6 060701-N0502-47 **1** Wash T1 Assembly, Mark-up Applied Not Applicable General Assembly Washing Equipment, LC **300 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$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)**

6 H-PLUNGER, VALVE BODY 060701-N0502-47 **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **300 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.00**

7 H-PLUNGER, VALVE BODY 060701-N0502-47A **1** Machine T1 Assembly, Mark-up Applied @ Bottom. MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA **132 1**  **2 1**  0.380 **$0.74 $36.98**  **$20.48 $40.96**  **$0.28 $0.28**  **$0.31 $0.87**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.87 $0.87**  **$0.28**

8 H-RETAINER INPUT ROD SPRING 060701-N0502-48 **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS **2000 0.5**  **1 1**  0.018 **$0.45 $42.73**  **$24.60 $24.60**  **$0.01 $0.01**  **$0.01 $0.03**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.03 $0.03**  **$0.01**

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-POPPET VALVE BODY 060701-N0502-49 **1** Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS **720 1**  **1 1**  0.013 **$1.32 $41.48**  **$16.39 $16.39**  **$0.02 $0.06**  **$0.02 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.02**

2 H-RETAINER POPPET SPRING 060701-N0502-50 **1** Mold T2/T3 Inject. Mold, SSLC PET-GF36 Mold/Cast/Sinter Operator Inject. Mold, SS **4000 1**  **1 1**  0.021 **$1.20 $41.48**  **$16.39 $16.39**  **$0.03 $0.01**  **$0.00 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04**  **$0.03**



### 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**



### 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 H-SPRING, INPUT ROD 060701-N0502-51 **1** S **$0.00** $0.17 **$0.00 $0.17**  **$0.17**

2 H- SPRING, POPPET VALVE 060701-N0502-52 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

3 H-WASHER, POPPET VALVE BODY 060701-N0502-53 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

4 H-SEAL, POPPET VALVE 060701-N0502-54 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06** 

### "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 4 H-SEAL, POPPET VALVE 060701-N0502-54 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

**Material**

**$0.74**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$91.45**

**T1 or OEM Total Manufacturing Cost: $0.74**  **$0.91 $0.86**  **$2.52 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  **$2.53**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.16**  **$0.15 $0.06**  **$0.39**

**Base Cost Impact to Vehicle: $0.74**  **$0.91 $0.86**  **$2.52 $0.01**  **$0.17 $0.16**  **$0.06 $0.41**  **$2.92 $0**  **$0** 

### "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

**3 1** 



### 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: 2 of 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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: $0.00** 

**Net Cost Impact to Vehicle: $2.92** 

**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** **)** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)**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** **/ N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******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********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 Cost Total: **$0.000** 

### 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 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: 3 of 6 

# 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)

H-INPUT ROD ASSEMBLY 060701-N0502-46

H-INPUT ROD, VALVE BODY 060701-N0502-46A

H-INPUT ROD, VALVE BODY 060701-N0502-46B

060701-N0502-47 

### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.29 $0.23**  **$0.52 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Attach plunger rod to body. Apply seal to greased poppet valve retainer. Place plunger spring in retainer, place valve body on top and insert plunger/body asm and compress. Apply metal retainer and slip on poppet valve spring. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 55 6 1 55 **1.0 2.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

Batch Wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.19 $0.21**  **$0.51 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 37 4 1 37 **1.0 2.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12 1 1 12 **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**

H-PLUNGER, VALVE BODY 060701-N0502-47

H-PLUNGER, VALVE BODY 060701-N0502-47A

H-RETAINER INPUT ROD SPRING 060701-N0502-48



## Purchase Part - High Impact Item (Full Cost Mapping)

H-POPPET VALVE BODY 060701-N0502-49

H-RETAINER POPPET SPRING 060701-N0502-50



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H-SPRING, INPUT ROD 060701-N0502-51

H- SPRING, POPPET VALVE 060701-N0502-52

H-WASHER, POPPET VALVE BODY 060701-N0502-53

H-SEAL, POPPET VALVE 060701-N0502-54 **$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

Batch Wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12 1 1 12 **1.0 1.0** 

**$0.28 $0.31**  **$0.87 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 54.5 8 1 54.5 **1.0 2.0** 

**$0.01 $0.01**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 1 1.8 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.06 $0.02**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  8 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 5 1 8 40 **1.0 1.0** 

**$0.01 $0.00**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.9 1 10 9 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.17**

**$0.05**

**$0.02**

**$0.06** H-SEAL, POPPET VALVE 060701-N0502-54

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.91 $0.86**  **$2.52 $0.00**  **$0.01 $0.01**  **$0.00 $0.01** 

**$2.53 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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: 5 of 6 

# 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)

H-INPUT ROD ASSEMBLY 060701-N0502-46

H-INPUT ROD, VALVE BODY 060701-N0502-46A

H-INPUT ROD, VALVE BODY 060701-N0502-46B

060701-N0502-47 

### 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!** 

-

**131 27.50**  1.00

**277 13.00**  0.25

**195 18.50**  1.00

**300 12.00**  0.25 H-PLUNGER, VALVE BODY 060701-N0502-47

H-PLUNGER, VALVE BODY 060701-N0502-47A

H-RETAINER INPUT ROD SPRING 060701-N0502-48



## Purchase Part - High Impact Item (Full Cost Mapping)

H-POPPET VALVE BODY 060701-N0502-49

H-RETAINER POPPET SPRING 060701-N0502-50



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H-SPRING, INPUT ROD 060701-N0502-51

H- SPRING, POPPET VALVE 060701-N0502-52

H-WASHER, POPPET VALVE BODY 060701-N0502-53

H-SEAL, POPPET VALVE 060701-N0502-54 **300 12.00**  0.25

**132 27.25**  1.00

**2000 1.80**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**720 5.00**  1.00

**4000 0.90**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H-SEAL, POPPET VALVE 060701-N0502-54



### 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 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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** 

### 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** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-KEY BOOSTER, MATE 060701-N0502-55 **1** Mold T2/T3 Inject. Mold, SSLC Thermoset-EPDM Mold/Cast/Sinter Operator Inject. Mold, SS **750 1**  **1 1**  0.006 **$1.83 $41.48**  **$16.39 $16.39**  **$0.01 $0.06**  **$0.02 $0.09**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.10 $0.10**  **$0.01**

2 H-KEY, BOOSTER, METAL 060701-N0502-55A **1** Stamp T2/T3 Stamp/Form, MSMC HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.103 **$0.65 $42.73**  **$15.50 $15.50**  **$0.07 $0.00**  **$0.00 $0.07**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.01**  **$0.08 $0.08**  **$0.07**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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**

**Material** 

### "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

**$0.08**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.18**

**T1 or OEM Total Manufacturing Cost: $0.08**  **$0.06 $0.02**  **$0.16 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  **$0.18**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.01**  **$0.01 $0.00**  **$0.03**

**Base Cost Impact to Vehicle: $0.08**  **$0.06 $0.02**  **$0.16 $0.00**  **$0.02 $0.02**  **$0.01 $0.05**  **$0.21 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.21**  **3 1** 



### 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: 2 of 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447**  

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base

**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 Cost Total: **$0.000** 

### 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 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: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-KEY BOOSTER, MATE 060701-N0502-55

H-KEY, BOOSTER, METAL 060701-N0502-55A



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.06 $0.02**  **$0.09 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4.8 1 10 48 **1.0 1.0** 

**$0.00 $0.00**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total Labor**  **Burden TMC**  **Scrape SG&A**  **Profit ED&T**  **Total**

**$0.06 $0.02**  **$0.16 $0.00**  **$0.01 $0.01**  **$0.00 $0.02** 

**$0.18 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-KEY BOOSTER, MATE 060701-N0502-55

H-KEY, BOOSTER, METAL 060701-N0502-55A



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**750 4.80**  1.00

**5143 0.70**  0.50

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 H-REACTION DISK ASSEMBLY 060701-N0502-56 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **225 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.04**  **$0.07 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $0.11**  **$0.00**

6 H-PISTON, REACTION DISK 060701-N0502-57 **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **257 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.04**  **$0.04 $0.08**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.08 $0.08**  **$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 H-PISTON, REACTION DISK 060701-N0502-57A **1** Machine T1 Assembly, Mark-up Applied @ Bottom. MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA **138 0.5**  **1 1**  0.020 **$0.74 $36.98**  **$20.48 $20.48**  **$0.01 $0.13**  **$0.15 $0.30**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.30 $0.30**  **$0.01**

8 H-RETAINER, REACTION DISK 060701-N0502-58 **1** 1 Wash Cycles thru machining T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.00 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.00**

9 H-RETAINER, REACTION DISK 060701-N0502-58A **1** Machine T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic

Load **176 1**  **2 1**  0.000 **$0.00 $36.98**  **$40.26 $80.52**  **$0.00 $0.21**  **$0.46 $0.67**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.67 $0.67**  **$0.00**

10 H-RETAINER, REACTION DISK 060701-N0502-58B **1** Stress Relief Heat Treat T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Heat Treat Operator T5-Al380, SMS **1613 1.5**  **1 1**  0.100 **$0.012 $47.72**  **$10.17 $10.17**  **$0.00 $0.04**  **$0.01 $0.05**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.05 $0.05**  **$0.00**

11 H-RETAINER, REACTION DISK 060701-N0502-58C **1** Cast T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, SS **1241 1**  **1 1.1**  0.100 **$1.10 $41.48**  **$70.80 $77.88**  **$0.11 $0.03**  **$0.06 $0.21**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.21 $0.21**  **$0.11**

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 H-REACTION DISK 060701-N0502-59 **1** Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS **450 1**  **1 1**  0.017 **$1.32 $41.48**  **$16.39 $16.39**  **$0.02 $0.09**  **$0.04 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.17 $0.17**  **$0.02**

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**



### 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**



### 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 Cost**  **Unit PIA** 

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  **$0.00 $0.00**  **$0.00**

**Material** 

### "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.



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**$0.15**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.17**

**T1 or OEM Total Manufacturing Cost: $0.15**  **$0.63 $0.86**  **$1.64 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  **$1.65**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.11**  **$0.10 $0.04**  **$0.26**

**Base Cost Impact to Vehicle: $0.15**  **$0.63 $0.86**  **$1.64 $0.01**  **$0.12 $0.11**  **$0.04 $0.27**  **$1.91 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.91**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-REACTION DISK ASSEMBLY 060701-N0502-56

H-PISTON, REACTION DISK 060701-N0502-57



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.04 $0.07**  **$0.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Place piston into retainer and insert reation disk **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 16 1 1 16 **1.0 1.0** 

**$0.04 $0.04**  **$0.08 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14 1 1 14 **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**

H-PISTON, REACTION DISK 060701-N0502-57A

H-RETAINER, REACTION DISK 060701-N0502-58

H-RETAINER, REACTION DISK 060701-N0502-58A

H-RETAINER, REACTION DISK 060701-N0502-58B

H-RETAINER, REACTION DISK 060701-N0502-58C



## Purchase Part - High Impact Item (Full Cost Mapping)

H-REACTION DISK 060701-N0502-59



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.13**  **$0.15 $0.30**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 26.0 6 1 26.0 **1.0 1.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.21 $0.46**  **$0.67 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  EC 300 - Al Horizontal CNC. Various Milling, boring, chamfer, drilling and tapping operations **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 41 5 1 41 **1.0 2.0** 

**$0.04 $0.01**  **$0.05 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  T5 Heat Treat, 7.5 hour cycle, 12,100 per cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 12,100 27,000 **1.0 1.0** 

**$0.03 $0.06**  **$0.21 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Die Cast 0-500 ton, 12 cavity, Used 1.1 Multiplier for Trimming operation **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2.9 2 12 34.8 **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** 

**$0.09 $0.04**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 8 1 10 80 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$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**



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**$0.63 $0.86**  **$1.64 $0.00**  **$0.01 $0.01**  **$0.00 $0.02** 

**$1.65 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: 5 of 6 

# 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)

H-REACTION DISK ASSEMBLY 060701-N0502-56

H-PISTON, REACTION DISK 060701-N0502-57



### 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!** 

-

**225 16.00**  0.25

**257 14.00**  0.25

H-PISTON, REACTION DISK 060701-N0502-57A

H-RETAINER, REACTION DISK 060701-N0502-58

H-RETAINER, REACTION DISK 060701-N0502-58A

H-RETAINER, REACTION DISK 060701-N0502-58B

H-RETAINER, REACTION DISK 060701-N0502-58C



## Purchase Part - High Impact Item (Full Cost Mapping)

H-REACTION DISK 060701-N0502-59



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 138**  **26.00** 0.50

**277 13.00**  0.25

**176 20.50**  1.00

**1613 2.23**  1.50

**1241 2.90**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**450 8.00**  1.00

**#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 H - OUTPUT ROD ASSEMBLY 060701-N0502-60 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **206 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.19**  **$0.15 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**

4 H-ROD OUTPUT 060701-N0502-61 **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.00**

5 H-ROD OUTPUT 060701-N0502-61A **1** Machine T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LMC,

Automatic Load **195 1**  **2 1**  0.000 **$0.00 $36.98**  **$46.82 $93.64**  **$0.00 $0.19**  **$0.48 $0.67**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.67 $0.67**  **$0.00**

T1 Assembly, Mark-up Applied 

### 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)**

6 H-ROD OUTPUT 060701-N0502-61B **1** Forge T1 Assembly, Mark-up Applied @ Bottom. MC-Steel-1018, Bar Forging Operator Forge, SS **4000 2**  **1 1**  0.112 **$0.74 $40.18**  **$115.72 $115.72**  **$0.08 $0.02**  **$0.03 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.08**

7 H-SOCKET, OUTPUT ROD 060701-N0502-62 **1** Batch Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.00**

8 H-SOCKET, OUTPUT ROD 060701-N0502-62A **1** Pre cut bar, machined T1 Assembly, Mark-up Applied @ Bottom. HC-Steel-1040S, Bar CNC Operator DS-CNC Turning, SMS, BF,

DA **124 0.5**  **1 1**  0.020 **$0.80 $36.98**  **$27.76 $27.76**  **$0.02 $0.15**  **$0.22 $0.39**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.39 $0.39**  **$0.02**

9 H-SOCKET, OUTPUT ROD 060701-N0502-62 **1** Batch Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.00**

9 H-RETAINER, OUTPUT ROD 060701-N0502-62B **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming Operator Stamp/Form, XSS **6000 0.5**  **1 1**  0.046 **$0.74 $42.73**  **$24.60 $24.60**  **$0.03 $0.00**  **$0.00 $0.04**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.04 $0.04**  **$0.03**

10 **0 #####**  **0 1**  **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**  **$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**



### 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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 H-WASHER, OUTPUT ROD .59 060701-N0502-63 **1** S **$0.00** $0.005 **$0.00 $0.01**  **$0.01**

3 H-WASHER, OUTPUT ROD .10 060701-N0502-64 **1** S **$0.00** $0.005 **$0.00 $0.01**  **$0.01** 

### "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



### 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 6 

# 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 Brake Booster Assembly(Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

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**

**Material**

**$0.14**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.34**

**T1 or OEM Total Manufacturing Cost: $0.14**  **$0.65 $1.00**  **$1.80 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.80** 

### "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for
Mark

- up Calculations.

**3 1** 



### Notes: **T1 or OEM Total Manufacturing Cost: $0.14**  **$0.65 $1.00**  **$1.80 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.80**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.12**  **$0.11 $0.04**  **$0.28**

**Base Cost Impact to Vehicle: $0.14**  **$0.65 $1.00**  **$1.80 $0.01**  **$0.12 $0.11**  **$0.04 $0.28**  **$2.08 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.08** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Notes: a) Items 1,2, & 3 must all equal same value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H - OUTPUT ROD ASSEMBLY 060701-N0502-60

H-ROD OUTPUT 060701-N0502-61

H-ROD OUTPUT 060701-N0502-61A



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.19 $0.15**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Press Socket, Output rod, washers and retainer together **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 35 1 1 35 **1.0 2.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.19 $0.48**  **$0.67 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  CNC Turning, 2 axis, SL-10 **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 37 6 1 37 **1.0 2.0**  

### 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**

H-ROD OUTPUT 060701-N0502-61B

H-SOCKET, OUTPUT ROD 060701-N0502-62

H-SOCKET, OUTPUT ROD 060701-N0502-62A

H-SOCKET, OUTPUT ROD 060701-N0502-62

H-RETAINER, OUTPUT ROD 060701-N0502-62B



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) $0.02**  **$0.03 $0.13**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** 500 Ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.9 1 1 0.9 **1.0 1.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.15 $0.22**  **$0.39 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  TL-15 Turning , 4 axis, Twin Spindle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 29 6 1 29 **1.0 1.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Washer Duo 400 Wash Rinse & Dry, batch 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**  **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.6 1 1 0.6 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-WASHER, OUTPUT ROD .59 060701-N0502-63

H-WASHER, OUTPUT ROD .10 060701-N0502-64 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.01**

**$0.01**



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.65 $1.00**  **$1.80 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.80 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: 5 of 6 

# 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)

H - OUTPUT ROD ASSEMBLY 060701-N0502-60

H-ROD OUTPUT 060701-N0502-61

H-ROD OUTPUT 060701-N0502-61A



### 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!** 

-

**206 17.50**  1.00

**277 13.00**  0.25

**195 18.50**  1.00

H-ROD OUTPUT 060701-N0502-61B

H-SOCKET, OUTPUT ROD 060701-N0502-62

H-SOCKET, OUTPUT ROD 060701-N0502-62A

H-SOCKET, OUTPUT ROD 060701-N0502-62

H-RETAINER, OUTPUT ROD 060701-N0502-62B



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) 4000**  **0.90** 2.00

**277 13.00**  0.25

**124 29.00**  0.50

**277 13.00**  0.25

**6000 0.60**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#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 - Commodity ( Value taken from Purchase Part Database)

H-WASHER, OUTPUT ROD .59 060701-N0502-63

H-WASHER, OUTPUT ROD .10 060701-N0502-64 **#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: 6 of 6 

# 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 6 

# 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 Brake Booster Assembly, (Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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**

**0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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)**

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**



### 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**



### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 H-SOLENOID W SEAL, BOOSTER 060701-N0502-65 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **189 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.08 $0.13**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.14 $0.14**  **$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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 H- LIP SEAL, SOLENOID BOOSTER 060701-N0502-66 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

3 H-SOLENOID BOOSTER 060701-N0502-67 **1** S **$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**

**Material**

**$0.03** 

### "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.



### 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 6 

# 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 Brake Booster Assembly, (Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.17**

**T1 or OEM Total Manufacturing Cost: $0.03**  **$0.05 $0.08**  **$0.16 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  **$0.17**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.01**  **$0.01 $0.00**  **$0.03**

**Base Cost Impact to Vehicle: $0.03**  **$0.05 $0.08**  **$0.16 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  **$0.20 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.20**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **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)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

H-SOLENOID W SEAL, BOOSTER 060701-N0502-65



## 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** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.05 $0.08**  **$0.13 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  Apply seal to Solenoid Booster **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19 1 1 19 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

H- LIP SEAL, SOLENOID BOOSTER 060701-N0502-66

H-SOLENOID BOOSTER 060701-N0502-67 **$0.00**

**$0.03**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.05 $0.08**  **$0.16 $0.00**  **$0.01 $0.01**  **$0.00 $0.01** 



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**$0.17 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: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

H-SOLENOID W SEAL, BOOSTER 060701-N0502-65



## 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!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**189 19.00**  0.25

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H- LIP SEAL, SOLENOID BOOSTER 060701-N0502-66

H-SOLENOID BOOSTER 060701-N0502-67



### 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 6 

# 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 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 H-FRONT SHELL ASSEMBLY,BRAKE

BOOSTER 060701-N0502-68 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **129 6**  **6 1**  0.000 **$0.00 $38.55**  **$15.00 $90.00**  **$0.00 $1.80**  **$0.70 $2.50**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$2.50 $2.50**  **$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)**

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**



### 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 H-RETAINER,FRONT SHELL 060701-N0502-69 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **383 1**  **1 1**  0.035 **$1.54 $41.48**  **$16.39 $16.39**  **$0.05 $0.11**  **$0.04 $0.21**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.23 $0.23**  **$0.05**

3 H-RETAINER,FRONT SHELL 060701-N0502-70 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **383 1**  **1 1**  0.035 **$1.54 $41.48**  **$16.39 $16.39**  **$0.05 $0.11**  **$0.04 $0.21**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.23 $0.23**  **$0.05**

4 H-HARNESS RETAINER, FRONT SHELL 060701-N0502-71 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **281 1**  **1 1**  0.025 **$1.54 $41.48**  **$16.39 $16.39**  **$0.04 $0.15**  **$0.06 $0.24**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.27 $0.27**  **$0.04**

5 H-VACUUM HOSE SEAL,FRONT SHELL 060701-N0502-72 **1** Mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1200 1**  **1 1**  0.011 **$0.99 $41.48**  **$16.39 $16.39**  **$0.01 $0.03**  **$0.01 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.07 $0.07**  **$0.01**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 H-O RING, RETAINER,FRONT SHELL 060701-N0502-73 **1** S **$0.00** $0.09 **$0.00 $0.09**  **$0.09**

3 H-O RING SENSOR,FRONT SHELL 060701-N0502-74 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

4 H-C CLIP, FRONT SHELL 060701-N0502-75 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

5 H-O RING, RETAINER,FRONT SHELL 060701-N0502-76 **1** S **$0.00** $0.09 **$0.00 $0.09**  **$0.09**

6 H-O RING SENSOR,FRONT SHELL 060701-N0502-77 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

7 H-C CLIP, FRONT SHELL 060701-N0502-78 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

8 H-ELECTRICAL HARNESS, FRONT SHELL 060701-N0502-79 **1** S **$0.00** $1.75 **$0.00 $1.75**  **$1.75**

9 H-O RING, RETAINER,FRONT SHELL 060701-N0502-80 **1** S **$0.00** $0.09 **$0.00 $0.09**  **$0.09**

10 H-O RING, RETAINER,SMALL,FRONT SHELL 060701-N0502-81 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for
Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.



### 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 6 

# 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 Brake Booster Assembly, Populated**  

## Part Number: **060701-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$2.38**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$4.94**

**T1 or OEM Total Manufacturing Cost: $2.38**  **$2.20 $0.86**  **$5.43 $0.00**  **$0.04 $0.03**  **$0.00 $0.07**  **$5.51**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.03 $0.36**  **$0.33 $0.14**  **$0.85**

**Base Cost Impact to Vehicle: $2.38**  **$2.20 $0.86**  **$5.43 $0.03**  **$0.40 $0.36**  **$0.14 $0.93**  **$6.36 $0**  **$0 3**  **1**



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $6.36** 

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

H-FRONT SHELL ASSEMBLY,BRAKE

BOOSTER 060701-N0502-68



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **1 1**  **10 10**  **47 470**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$1.80 $0.70**  **$2.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Six station, Six operator - Insert vacuum hose seal into front shell. Push vacuum hose fitting in place. Lubricate first front shellretainer and apply O-ring. Snap retainer into front shell. Apply o-ring on position sensor and push into retainer. Fasten with cclip. Lubricate second front shell retainer and applu O-ring. Snap retainer into front shell. Apply o-ring onto pressure sensor and push into retainer.Fasten with c-clip.Apply lubricate to electrical harness connector, front shell. Place large then small o-ring connectors onto plug. Push into harness retainer and twist them in place on front shell. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 168 20 1 168 **1.0 6.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

H-RETAINER,FRONT SHELL 060701-N0502-69

H-RETAINER,FRONT SHELL 060701-N0502-70

H-HARNESS RETAINER, FRONT SHELL 060701-N0502-71

H-VACUUM HOSE SEAL,FRONT SHELL 060701-N0502-72



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.11 $0.04**  **$0.21 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  4 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9.4 1 4 37.6 **1.0 1.0** 

**$0.11 $0.04**  **$0.21 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  4 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9.4 1 4 37.6 **1.0 1.0** 

**$0.15 $0.06**  **$0.24 $0.00**  **$0.01 $0.01**  **$0.00 $0.03**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12.8 1 10 128 **1.0 1.0** 

**$0.03 $0.01**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 3 1 10 30 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

H-O RING, RETAINER,FRONT SHELL 060701-N0502-73

H-O RING SENSOR,FRONT SHELL 060701-N0502-74

H-C CLIP, FRONT SHELL 060701-N0502-75

H-O RING, RETAINER,FRONT SHELL 060701-N0502-76

H-O RING SENSOR,FRONT SHELL 060701-N0502-77

H-C CLIP, FRONT SHELL 060701-N0502-78

H-ELECTRICAL HARNESS, FRONT SHELL 060701-N0502-79

H-O RING, RETAINER,FRONT SHELL 060701-N0502-80

H-O RING, RETAINER,SMALL,FRONT SHELL 060701-N0502-81 **$0.00**

**$0.09**

**$0.05**

**$0.02**

**$0.09**

**$0.05**

**$0.02**

**$1.75**

**$0.09**

**$0.06**

**$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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$2.20 $0.86**  **$5.43 $0.00**  **$0.04 $0.03**  **$0.00 $0.07** 

**$5.51 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: 5 of 6 

# 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)

H-FRONT SHELL ASSEMBLY,BRAKE

BOOSTER 060701-N0502-68



### 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!** 

**129 28.00**  6.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H-RETAINER,FRONT SHELL 060701-N0502-69

H-RETAINER,FRONT SHELL 060701-N0502-70

H-HARNESS RETAINER, FRONT SHELL 060701-N0502-71

H-VACUUM HOSE SEAL,FRONT SHELL 060701-N0502-72



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**383 9.40**  1.00

**383 9.40**  1.00

**281 12.80**  1.00

**1200 3.00**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H-O RING, RETAINER,FRONT SHELL 060701-N0502-73

H-O RING SENSOR,FRONT SHELL 060701-N0502-74

H-C CLIP, FRONT SHELL 060701-N0502-75

H-O RING, RETAINER,FRONT SHELL 060701-N0502-76

H-O RING SENSOR,FRONT SHELL 060701-N0502-77

H-C CLIP, FRONT SHELL 060701-N0502-78

H-ELECTRICAL HARNESS, FRONT SHELL 060701-N0502-79

H-O RING, RETAINER,FRONT SHELL 060701-N0502-80

H-O RING, RETAINER,SMALL,FRONT SHELL 060701-N0502-81



### 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 6 

# 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 6 

# 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 Brake Booster Assembly, (Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 H- FRONT SHELL ASM, PAINTED 060701-N0502-82 **1** Paint T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.03**  **$0.05 $0.09**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.09 $0.09**  **$0.00**

2 H- FRONT SHELL ASM, WASHED 060701-N0502-82A **1** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $0.11**  **$0.00**

3 H- FRONT SHELL ASM, PRESSED

TOGETHER 060701-N0502-82B **1** Press T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **124 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.08**  **$0.12 $0.20**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.20 $0.20**  **$0.00**

3 H- FRONT SHELL, STAMPED 060701-N0502-82C **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS **493 0.5**  **1 1**  3.099 **$0.45 $42.73**  **$141.76 $141.76**  **$1.39 $0.04**  **$0.29 $1.73**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.73 $1.73**  **$1.39**

4 H-STUD PLATE, FRONT SHELL 060701-N0502-83 **1** Engrave T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **257 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.04**  **$0.06 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$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)**

4 H-STUD PLATE, FRONT SHELL 060701-N0502-83 **1** Engrave @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **257 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.04**  **$0.06 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**

5 H-STUD PLATE, FRONT SHELL 060701-N0502-83A **1** Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.615 **$0.45 $42.73**  **$15.50 $15.50**  **$0.28 $0.00**  **$0.00 $0.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.28 $0.28**  **$0.28**



### 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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 H-STUD PLATE WASHER, REAR SHELL 060701-N0502-84 **2** S **$0.00** $0.0450 **$0.00 $0.09**  **$0.09**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$1.76**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$2.59**

**T1 or OEM Total Manufacturing Cost: $1.76**  **$0.20 $0.54**  **$2.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$2.50** 

### "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

**3 1** 



### Notes: **T1 or OEM Total Manufacturing Cost: $1.76**  **$0.20 $0.54**  **$2.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$2.50**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.16**  **$0.15 $0.06**  **$0.39**

**Base Cost Impact to Vehicle: $1.76**  **$0.20 $0.54**  **$2.50 $0.01**  **$0.16 $0.15**  **$0.06 $0.39**  **$2.89 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.89**  

### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# 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 Brake Booster Assembly, (Master Cylinder Removed)**  

## Part Number: **060701-N0502-02** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# 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)

H- FRONT SHELL ASM, PAINTED 060701-N0502-82

H- FRONT SHELL ASM, WASHED 060701-N0502-82A

H- FRONT SHELL ASM, PRESSED

TOGETHER 060701-N0502-82B

H- FRONT SHELL, STAMPED 060701-N0502-82C

H-STUD PLATE, FRONT SHELL 060701-N0502-83



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.03 $0.05**  **$0.09 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Spray Paint **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.08 $0.12**  **$0.20 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Press Front Shell, Stud Plate and studs together **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 29 1 1 29 **1.0 1.0** 

**$0.04 $0.29**  **$1.73 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  1000 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 7.3 1 1 7.3 **1.0 1.0** 

**$0.04 $0.06**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Label Engraver **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14 1 1 14 **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**

H-STUD PLATE, FRONT SHELL 060701-N0502-83

H-STUD PLATE, FRONT SHELL 060701-N0502-83A



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H-STUD PLATE WASHER, REAR SHELL 060701-N0502-84 **$0.04 $0.06**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Label Engraver **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14 1 1 14 **1.0 1.0** 

**$0.00 $0.00**  **$0.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.09**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.20 $0.54**  **$2.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$2.50 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: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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: 5 of 6 

# 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)

H- FRONT SHELL ASM, PAINTED 060701-N0502-82

H- FRONT SHELL ASM, WASHED 060701-N0502-82A

H- FRONT SHELL ASM, PRESSED

TOGETHER 060701-N0502-82B

H- FRONT SHELL, STAMPED 060701-N0502-82C

H-STUD PLATE, FRONT SHELL 060701-N0502-83



### 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** 

**277 13.00**  0.25

**277 13.00**  0.25

**124 29.00**  0.25

**493 7.30**  0.50

**257 14.00**  0.25 H-STUD PLATE, FRONT SHELL 060701-N0502-83

H-STUD PLATE, FRONT SHELL 060701-N0502-83A



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H-STUD PLATE WASHER, REAR SHELL 060701-N0502-84 **257 14.00**  0.25

**5143 0.70**  0.50

**#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: 6 of 6 

# 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

# Indented Bill of Materials

**H Brake Booster A**

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

**H Brake Booster A**

**ssembly H Brake**  

# ###

**Booster A**

**sm, Populated** 

**1 H-REA**  **R SHELL W/PLA TES**  **H-REA R**  **1**

**SHELL**
**W/PLA TES** 

**2 H-REA**  **R SHELL W/STUDS H-REA**  **R 1** 

**SHELL**
**W/STUDS**

**3 H-REA**  **R SHELL-Press H-REA**  **R 1** 

**SHELL-Press**

**4 H-REA**  **R SHELL-Wash H-REA**  **R 1** 

**SHELL-WA**

**SH**

**5 H-REA**  **R SHELL, Stamping H-REA**  **R 1** 
**SHELL, Stamping** 

**6** H-REAR SHELL-Material H-REAR **1** Steel - 1008

SHELL

-Material

4 H-STUD, REAR SHELL H-STUD, 4 Commodity

REAR SHELL Pricing

**2 H-VA** 

**CUUM SEA L, REA**  **R H-VA**  **CUUM 1**  **Commodity**

**SHELL SEA**  **L, REA R**  **Pricing**
**SHELL**

**3** H-VACUUM SEAL, REAR - H-VACUUM **1** EDPM

Material SEAL, REAR
SHELLMaterial

2 H-FOAM GASKET, REAR H-FOAM 1 Commodity

SHELL GASKET, Pricing
REAR SHELL

**2 H-STUD PLA** 

**TE, REA R**  **H-STUD 1** 

**SHELL PLA**  **TE, REA R** 
**SHELL**

**3 H-STUD PLA** 

**TE, REA R**  **H-STUD 1** 

**SHELL -Wash PLA**  **TE, REA R** 
**SHELL-Wash**



# Design Profit

®

Page 1 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

**H-STUD PLA**

**TE, REA R**  **H-STUD**

**SHELL WELD PLA**  **TE, REA R** 

# SHELL WELD

**5 H-STUD PLA** 

**TE, REA R**  **H-STUD 1** 

**SHELL STA MPED**  **PLA TE, REA**  **R**
**SHELL**
**STA MPED** 

**6** H-STUD PLATE, REAR H-STUD **1** Steel - 1008

SHELL- Material PLATE, REAR
SHELL

-Material

5 H-STUD PLATE W ASHER, H-STUD 4 Commodity

REAR SHELL PLATE Pricing

WA SHER,
REAR SHELL

2 H-TINNERMAN NUT H- 4 Commodity

TINNERMAN Pricing
NUT

2 H FOAM SEAL, REAR SHELL H FOAM 1 Commodity
SEAL, REAR Pricing
SHELL

2 H-FOAM FILTER H-FOAM 1 Commodity

FILTER Pricing

**2 H-EXCLUDER**  **H-EXCLUDER 1**  **PP EDPM**

**3** H-EXCLUDER, Material H-EXCLUDER, **1** PP EDPM

Material

2 H-HOSE CLAMP, EXCLUDER H-HOSE 1 Commodity
CLAMP, Pricing
EXCLUDER

2 H-LOCK NUT, CLEVIS TO H-LOCK NUT, 1 Commodity

SHAFT CLEVIS TO Pricing
SHAFT

**2 H-CLEVIS TO PEDA**  **L H-CLEVIS TO**  **1 MIXED** 

**PEDA L** 

**3 H-CLEVIS TO PEDA**  **L, H-CLEVIS TO**  **1 MIXED** 

**OVERMOLDED PEDA**  **L,**
**OVERMOLDE**

**D**

**4 H-CLEVIS TO PEDA**  **L H-CLEVIS TO**  **1**

**PLA TED**  **PEDA L** 

**PLA TED** 

**5 H-CLEVIS TO PEDA**  **L, Wash H-CLEVIS TO**  **1**

**PEDA L, Wash**  

# Design Profit

®

Page 2 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material** 

**H-CLEVIS TO PEDA L,**  **H-CLEVIS TO**

**WELDMENT PEDA**  **L,**

**WELDMENT**

**7 H-SUPPORT, CLEVIS TO**  **H-SUPPORT, 1**  **Steel - 1008**

**PEDA L, Stamped**  **CLEVIS TO**

**PEDA L,**  **Stamped**

**8** H-SUPPORT, CLEVIS TO H-SUPPORT, **1** Steel - 1008
PEDAL, Material CLEVIS TO PEDAL,
Material

# 7 **H-CLEVIS TO PEDA L**  **H-CLEVIS TO 1**  **Steel - 1008**

**STA MPED**  **PEDA L** 
**STA MPED** 

**8** H-CLEVIS TO PEDAL, H-CLEVIS TO **1** Steel - 1008

Material PEDAL,
Material

4 H-OVERMOLD, CLEVIS TO H- 1 ACETAL
PEDAL, Material OVERMOLD,
CLEVIS TO PEDAL,
Material

**3 H-BUMPER, CLEVIS TO**  **H-BUMPER, 2**  **PP EDPM**

**PEDA L**  **CLEVIS TO**

**PEDA L** 

**4** H-BUMPER, CLEVIS TO H-BUMPER, **1** PP EDPM
PEDAL, Material CLEVIS TO PEDAL,
Material

**2 H-CENTER SECTION,**  **H-CENTER 1** 

**BOOSTER SECTION,** 
**BOOSTER**

**3 H-PLA** 

**TES & DIA PHRA** 

**GMS H-PLA** 

**TES & 1** 

**DIA PHRA** 

**GMS**

**4 H-VA**  **LVE BODY W SEA L**  **H-VA LVE**  **1**

**BODY W**
**SEA L** 

**5 H-VA**  **LVE BODY- Molded H-VA**  **LVE 1**  **PET-GF 36**

**BODY-Molded**

**6** H-VALVE BODY - Material H-VALVE **1** PET-GF 36

BODY -

Material



# Design Profit

®

Page 3 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

H-SEAL, VALVE BODY SQ H-SEAL, 

# 1 Commodity

CUT- Molded VALVE BODY Pricing
SQ
CUT-Molded

**5 H-STA**  **R WA**

**SHER, VA LVE**  **H-STA R**  **1 Commodity** 

**BODY WA**  **SHER, Pricing** 

**VA LVE BODY** 

**6** H-STAR W ASHER, VALVE H-STAR **1** Steel - 1040

BODY-Material WA SHER,

VALVE
BODY-Material

**4 H-REA**  **R PLA**

**TE, DIA G, CUP**  **H-REA R**  **1**

**PLA TE, DIA**  **G,**
**CUP**

**5 H-REA**  **R H-REA**  **R 1**  **SBR**

**DIA PHRA** 

**GM-Molded DIA**  **PHRA GM** 

**Molded**

**6** H-REAR DIAPHRAGM - H-REAR **1** SBR

Material DIAPHRAGM -

# Material

**5 H-REA**  **R PLA**

**TE, CENTER H-REA**  **R 1**  **Steel - 1008**

**SECTION- Washed PLA**  **TE,**
**CENTER**
**SECTION**

**Wa shed** 

**6 H-REA**  **R PLA**

**TE, CENTER H-REA**  **R 1**  **Steel - 1008 SECTION- Stamping**  **PLA TE,** 
**CENTER**
**SECTION Stamping** 

**7** H-REAR PLATE, CENTER H-REAR **1** Steel - 1008

SECTION-Material PLATE,
CENTER
SECTION

-Material

**5 H-REA**  **R CUP, CENTER H-REA**  **R CUP, 1**  **Steel - 1008**

**SECTION CENTER** 
**SECTION**

**6 H-REA**  **R CUP, CENTER H-REA**  **R CUP, 1**  **Steel - 1008**

**SECTION-Washed CENTER** 
**SECTION**

**Wa shed** 



# Design Profit

®

Page 4 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material** 

**7 H-REA**  **R CUP, CENTER H-REA**  **R CUP, Steel - 1008**  **SECTION- Stamping CENTER** 
**SECTION Stamping** 

**8** H-REAR CUP, CENTER H-REAR CUP, **1** Steel - 1008

SECTION-Material CENTER
SECTION

-Material

**4 H-CENTER PLA** 

**TE W SEA L**  **H-CENTER 1** 

**PLA TE W** 
**SEA L** 

**5 H-CENTER PLA** 

**TE H-CENTER**  **1 Steel - 1008** 

**PLA TE** 

**6 H-CENTER PLA** 

**TE- Stamping H-CENTER**  **1 Steel - 1008** 

**PLA TE**  **Stamping**

**7** H-CENTER PLATE-Material H-CENTER **1** Steel - 1008

PLATE
-Material

**5 H-SEA**  **L, CENTER PLA TE-**  **H-SEA L,**  **1 EDPM** 

**Molded CENTER** 

**PLA TE** 
**Molded**

**6** H-SEAL, CENTER PLATE- H-SEAL, **1** EPDM

Material CENTER

PLATE
-Material

**4 H-FRONT PLA** 

**TE H-FRONT**  **1 Steel - 1018** 

# PLA **TE**

**5 H-FRONT PLA** 

**TE, Stamped H-FRONT**  **1 Steel - 1018** 

**PLA TE,**  **Stamped**

**6** H-FRONT PLATE BLANK H-FRONT **1** Steel - 1018

PLATE BLANK

**4 H-CENTER DIA**  **PHRA GM-**  **H-CENTER 1**  **SBR**

**Molded DIA**  **PHRA GM** 

**Molded**

**5** H-CENTER DIAPHRAGM - H-CENTER **1** SBR

Material DIAPHRAGM

-Material



# Design Profit

®

Page 5 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

**H-C0NNECTOR, INPUT ROD H** 

**TO SOLENOID C0NNECTOR,** 
**INPUT ROD**
**TO**
**SOLENOID**

**4 H-HOUSING, CONNECTOR-**  **H-HOUSING, 1**  **PPS GF40**

**Molded CONNECTOR** 

**Molded**

**5** H-HOUSING, CONNECTOR - H-HOUSING, **1** PPS GF40

Material CONNECTOR

- Material

4 H-SEAL, CONNECTOR- H-SEAL, 1 Commodity

Molded CONNECTOR- Pricing
Molded

4 H-W AVE W ASHER, H-W AVE 1 Commodity

CONNECTOR WA SHER, Pricing
CONNECTOR

4 H-W ASHER, CONNECTOR H-W ASHER, 1 Commodity

CONNECTOR Pricing

**4 H-RETA**  **INER, CONNECTOR- H-RETA**  **INER, 1**  **PPS GF40**

**Molded CONNECTOR** 

**Molded**

**5** H-RETAINER, CONNECTOR H-RETAINER, **1** PPS GF40

-Material CONNECTOR

-Material

**3 H-INPUT ROD A** 

**SSEMBLY H-INPUT ROD**  **1**

**AS SEMBLY** 

**4 H-INPUT ROD, VA**  **LVE BODY H-INPUT ROD,**  **1 Steel - 1018** 

**VA LVE BODY** 

**5 H-INPUT ROD, VA**  **LVE H-INPUT ROD,**  **1 Steel - 1018** 

**BODY-Machined VA**  **LVE**
**BODY**

**Machined**

**6** H-INPUT ROD, VALVE H-INPUT ROD, **1** Steel - 1018

BODY-Material VALVE
BODY-Material

**4 H-RETA**  **INER, INPUT ROD H-RETA**  **INER, 1**  **Steel - 1008**

# SPRING **INPUT ROD**
**SPRING**

**5** H-RETAINER, INPUT ROD H-RETAINER, **1** Steel - 1008

SPRING-Material INPUT ROD
SPRINGMaterial 

# Design Profit

®

Page 6 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

H-SPRING, INPUT ROD H-SPRING, 

# 1 Commodity

INPUT ROD Pricing

**4 H-RETA**  **INER, POPPET H-RETA**  **INER, 1**  **PET-GF 36**

**SPRING WITH SEA L**  **POPPET**
**SPRING WITH**
**SEA L** 

**5** H-RETAINER, POPPET H-RETAINER, **1** PET-GF 36

SPRING W ITH SEAL-Material POPPET
SPRIN W ITH
SEAL-Material

4 H-SPRING, POPPET VALVE H-SPRING, 1 Commodity

POPPET Pricing

VALVE

**4 H-POPPET, VA**  **LVE BODY H-POPPET,**  **1**

**VA LVE BODY** 

**5** H-W ASHER, POPPET, VALVE H-W ASHER, **1** Commodity

BODY-Material POPPET, Prcing
VALVE BODY

5 H-POPPET, VALVE H-POPPET, 1 SBR

BODY-Material VALVE
BODY-Material

**4 H-PLUNGER VA**  **LVE BODY H-PLUNGER**  **1 Steel - 1018** 

**VA LVE BODY** 

**5 H-PLUNGER VA**  **LVE BODY H-PLUNGER**  **1 Steel - 1018** 

**VA LVE** 
**BODY**

**Machined**

**6** H-PLUNGER, VALVE BODY H-PLUNGER, **1** Steel - 1018

BAR STOCK VALVE BODY
BAR STOCK

4 H SEAL, POPPET VALVE H SEAL, 1 Commodity

POPPET Pricing

VALVE

**3 H KEY, BOOSTER**  **H KEY, 1** 

**BOOSTER**

**4** H KEY, BOOSTER-Material H KEY, **1** EDPM

BOOSTERMaterial

**4 H Metal KEY, BOOSTER**  **H Metal KEY, 1**  **Steel - 1040**

**BOOSTER**

**5** H Metal KEY, H Metal KEY, **1** Steel - 1040

BOOSTER-Material BOOSTERMaterial 

# Design Profit

®

# Page 7 of #

Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

**H Solenoid w Seal, Booster H Solenoid w**  **Seal, Booster**

**3 H Solenoid, Booster**  **H Solenoid, 1**  **Commodity**

**Booster Pricing** 

**3** H Lip Seal, Booster, Solenoid H Lip Seal, **1** Commodity
Booster, Pricing
Solenoid

2 H Screw, Solenoid to Shaft H Screw, 1 Commodity

Solenoid to Pricing
Shaft

**2 H-REA** 

**CTION DISK H-REA**  **CTION 1** 

**AS SEMBLY**  **DISK**
**AS SEMBLY** 

**3 H Retainer, Reaction Disc**  **H Retainer, 1**  **A3 80** 

**Reaction Disc**

**4 H Retainer, Reaction Disc,**  **H Retainer, 1** 

**Machined Reaction**  **Disc,**
**Machined**

**5 H Retainer, Reaction Disc,**  **H Retainer, 1** 

**Trimed Reaction**  **Disc, Trimed**

**6 H Retainer, Reaction Disc,**  **H Retainer, 1** 

**Die Cast Reaction**  **Disc, Die Cast**

**7** H Retainer, Reaction Disc, H Retainer, **1** A380

Material Reaction Disc,
Material

**3 H Piston, Reaction Disc**  **H Piston, 1**  **Steel - 1018**

**Reaction Disc**

**4 H Piston, Reaction Disc,**  **H Piston, 1**  **Steel - 1018**

**Turned Reaction**  **Disc, Turned**

**5** H Piston, Reaction Disc, H Piston, **1** Steel - 1018

Material Reaction Disc,
Material

**3 H Reaction Disc**  **H Reaction 1**  **SBR**

**Disc**

**4** H Reaction Disc, Material H Reaction **1** SBR
Disc, Material

**2 H Output Rod A** 

**ssembly H Output Rod**  **1**

**As sembly** 



# Design Profit

®

Page 8 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

# H Rod Output **H Rod Output Steel - 1018** 

**4 H Rod Output, Machined**  **H Rod Output, 1**  **Steel - 1018**

**Machined**

**5 H Output Rod, Forged**  **H Output Rod, 1**  **Steel - 1018 Forged** 

**6** H Output Rod, Material H Output Rod, **1** Steel - 1018

Material

3 H W asher, Output Rod, 0.59 H W asher, 1 Commodity

mm Output Rod, Pricing
0.59 mm

3 H W asher, Output Rod, 0.10 H W asher, 1 Commodity

mm Output Rod, Pricing
0.10 mm

**3 H Socket, Output Rod**  **H Socket, 1**  **Steel - 1040 Output Rod** 

**4 H Socket, Output Rod,**  **H Socket, 1**  **Steel - 1040**

**Machined Output Rod,** 

**Machined**

**5** H Socket, Output Rod, Material H Socket, **1** Steel - 1040 Output Rod,

Material

**3 H Retainer, Output Rod**  **H Retainer, 1**  **Steel - 1008 Output Rod** 

**4 H Retainer, Output Rod,**  **H Retainer, 1**  **Steel - 1008 Stamped**  **Output Rod, Stamped** 

**5** H Retainer, Output Rod, H Retainer, **1** Steel - 1008

Material Output Rod,

Material

1 H Spring Large, Brake Booster H Spring 1 Commodity Large, Brake Pricing
Booster

**1 H Front Shell A** 

**sm, Brake H Front Shell**  **1**

**Booster As**  **m, Brake**
**Booster**

**2 H Front Shell A** 

**sm, Painted H Front Shell**  **1**

**As m, Painted** 

**3 H Front Shell A** 

**sm, Washed H Front Shell**  **1**

**As m, Washed** 

**4 H Front Shell A** 

**sm, Pressed H Front Shell**  **1 Steel - 1008**  **Together As**  **m, Pressed Together**  

# Design Profit

®

Page 9 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

**H Front Shell Outer, H Front Shell**  

# 1 **Steel - 1008 Stamped**  **Outer, Stamped** 

**6** H Front Shell, Material H Front Shell, **1** Steel - 1008

Material

**5 H Stud Plate, Front Shell,**  **H Stud Plate, 1**  **Steel - 1008 Engraved**  **Front Shell, Engraved** 

# 6 **H Stud Plate, Front Shell, H Stud Plate,**  **1 Steel - 1008**  **Stamped Front Shell,**  **Stamped**

**7** H Stud Plate, Front Shell, H Stud Plate, **1** Steel - 1008

Material Front Shell,

Material

5 H-Stud Short, Front Shell H-Stud Short, 2 Commodity

Front Shell Pricing

**2 H Vacuum Hose Seal, Front**  **H Vacuum 1**  **EPDM**

**Shell Hose Seal,** 
**Front Shell**

**3** H Vacuum Hose Seal, Front H Vacuum **1** EPDM
Shell, Material Hose Seal, Front Shell,

Material

**2 H Vacuum Hose Fitting,**  **H Vacuum 1**  **Commodity**

**Front Shell Hose Fitting,**  **Pricing**
**Front Shell**

**2 H Retainer, Front Shell**  **H Retainer, 1**  **PA 66 GF30** 

**Front Shell**

**3** H Retainer, Front Shell, H Retainer, **1** PA66 GF30

Material Front Shell,

Material

2 H O-Ring, Retainer, Front Shell H O-Ring, 1 Commodity
Retainer, Front Pricing
Shell

**2 H Position Sensor, Front**  **H Position 1**  **Commodity**

**Shell Sensor, Front**  **Pricing**
**Shell**

**2** H O-Ring, Sensor, Front Shell H O-Ring, **1** Commodity
Sensor, Front Pricing
Shell

2 H C-Clip, Front Shell H C-Clip, Front 1 Commodity

Shell Pricing



# Design Profit

®

Page 10 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**

**H Retainer, Front Shell H Retainer,**  **PA 66 GF30** 

**Front Shell**

**3** H Retainer, Front Shell, H Retainer, **1** PA66 GF30

Material Front Shell,

Material

2 H O-Ring, Retainer, Front Shell H O-Ring, 1 Commodity
Retainer, Front Pricing
Shell

**2 H Pressure Sensor, Front**  **H Pressure 1**  **Commodity**

**Shell Sensor, Front**  **Pricing**
**Shell**

**2** H O-Ring, Sensor, Front Shell H O-Ring, **1** Commodity
Sensor, Front Pricing
Shell

2 H C-Clip, Front Shell H C-Clip, Front 1 Commodity

Shell Pricing

# 2 **H Electrical Harness, Front H Electrical**  **1 Commodity** 

**Shell Harness,**  **Pricing**
**Front Shell**

**2** H O-Ring, Retainer, Front Shell H O-Ring, **1** Commodity
Retainer, Front Pricing
Shell

2 H O-Ring, Retainer Small, H O-Ring, 1 Commodity

Front Shell Retainer Small, Pricing
Front Shell

**2 H Harness Retainer, Front**  **H Harness 1** 

**Shell Retainer,** 
**Front Shell**

**3** H Harness Retainer, Front H Harness **1** PA66 GF30
Shell, Material Retainer, Front Shell, Material

1 H Label, Brake Booster, Front H Label, Brake 1 Commodity

Shell Booster, Front Pricing
Shell

**0 H MA** 

**STER CYLINDER H MA**  **STER 1**  **Commodity $0.00** 

**CYLINDER Price** 

**0** H Nut, Cylinder to Booster H Nut, Cylinder **2** Commodity **$0.07**

to Booster Price

**0 H Vacuum Hose, Booster**  **H Vacuum 1**  **$0.00**
**Hose, Booster**



# Design Profit

®

Page 11 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost**



# Assembly Totals 

# Report Totals

**An aly**  **zed Subs:**

84 

# Piece Cost (Total): $11.36

**Unanaly zed Subs:**  4 

# Weight (Total): 11.7095 lb

**Parts:** 82

**Fasteners:** 16
**Parts+Unanaly**

**zed:** 86

# Design Profit ®

Page 12 of # Copyright 2005© Munro & Associates, Inc.

# Weight **Piece Cost Weight (Total)** 

**(Total)** 

# 10.0835 lb **### 10.0835 lb** 

**$6.75 7.1827 lb**  **$6.75 7.1827 lb** 

**$1.63 2.3340 lb**  **$1.63 2.3340 lb** 

**$1.63 2.3340 lb**  **$1.63 2.3340 lb** 

**$1.38 2.1500 lb**  **# 2.1500 lb** 

**$1.38 2.1500 lb**  **$1.38 2.1500 lb** 

**# 2.1500 lb**  **$1.38**

$0.06 0.0460 lb # 0.1840 lb

**$0.04 0.0146 lb**  **$0.04 0.0146 lb** 

**$0.04 0.0146 lb**  **$0.04 0.0146 lb** 

$0.08 0.0007 lb $0.08 0.0007 lb

**$0.13 0.2219 lb**  **$0.13 0.2219 lb** 

**$0.13 0.2219 lb**  **$0.13 0.2219 lb** 



# Piece Cost **Weight Piece Cost**  **Weight (Total)**

**(Total) $0.13**  **0.2219 lb**

# $0.10 **0.1939 lb $0.10**  **0.1939 lb**

**# 0.1939 lb**  **$0.10**

$0.01 0.0070 lb $0.03 0.0280 lb

$0.01 0.0009 lb $0.04 0.0036 lb

$0.06 0.0000 lb $0.06 0.0000 lb

$0.06 0.0023 lb $0.06 0.0023 lb

**$0.06 0.0382 lb**  **$0.06 0.0382 lb** 

**$0.06 0.0382 lb**  **$0.06 0.0382 lb** 

$0.00 0.0152 lb $0.00 0.0152 lb

$0.05 0.0199 lb $0.05 0.0199 lb

**$0.31 0.2774 lb**  **$0.31 0.2774 lb** 

**$0.30 0.2750 lb**  **$0.30 0.2750 lb** 

**$0.26 0.2410 lb**  **# 0.2410 lb** 

**$0.26 0.2410 lb**  **$0.26 0.2410 lb** 



# Piece Cost **Weight Piece Cost**  **Weight (Total)**

**(Total)**

**0.2410 lb $0.26** 

**$0.04 0.0300 lb**  **#**

**# 0.0300 lb**  **#**

# $0.22 **0.2110 lb #** 

**# 0.2110 lb**  **#**

$0.05 0.0340 lb # 0.0340 lb

**$0.01 0.0012 lb**  **$0.01 0.0024 lb** 

**$0.01 0.0012 lb**  **# 0.0024 lb** 

**$3.93 3.5132 lb**  **$3.93 3.5132 lb** 

**$2.94 2.9772 lb**  **$2.94 2.9772 lb** 

**$0.32 0.1778 lb**  **# 0.1778 lb** 

**$0.25 0.1769 lb**  **$0.25 0.1769 lb** 

**# 0.1769 lb**  **$0.25**



# Piece Cost **Weight Piece Cost**  **Weight (Total)**

**(Total)** $0.06 0.0000 lb $0.06

**$0.01 0.0009 lb**  **$0.01 0.0009 lb** 

**# 0.0009 lb**  **$0.01**

**$0.94 1.0258 lb**  **# 1.0258 lb** 

**$0.31 0.2550 lb**  **$0.31 0.2550 lb** 

**# 0.2550 lb**  **$0.31**

# $0.45 **0.4450 lb $0.45**  **0.4450 lb**

**# 0.4450 lb**  **$0.45**

**$0.45 0.4450 lb**  **#**

**$0.17 0.3258 lb**  **$0.17 0.3258 lb** 

**# 0.3258 lb**  **$0.17**



# Piece Cost **Weight Piece Cost**  **Weight (Total)**

**(Total) $0.17**  **0.3258 lb**

**# 0.3258 lb**  **#**

**$0.78 0.9236 lb**  **# 0.9236 lb** 

**$0.74 0.9000 lb**  **$0.74 0.9000 lb** 

**# 0.9000 lb**  **$0.74**

**$0.74 0.9000 lb**  **#**

**$0.04 0.0236 lb**  **$0.04 0.0236 lb** 

**# 0.0236 lb**  **$0.04**

**$0.66 0.6450 lb**  **# 0.6450 lb** 

# $0.66 **0.6450 lb $0.66**  **0.6450 lb**

**# 0.6450 lb**  **$0.66**

**$0.25 0.2050 lb**  **# 0.2050 lb** 

**$0.25 0.2050 lb**  **$0.25 0.2050 lb** 



# Weight **Piece Cost Weight (Total)** 

**(Total) $0.27**  **0.0156 lb $0.27** 

**$0.10 0.0105 lb**  **# 0.0105 lb** 

**$0.10 0.0105 lb**  **$0.10 0.0105 lb** 

$0.06 0.0000 lb # 0.0000 lb

$0.09 0.0027 lb # 0.0027 lb

$0.01 0.0007 lb # 0.0007 lb

**$0.02 0.0017 lb**  **# 0.0017 lb** 

**$0.02 0.0017 lb**  **$0.02 0.0017 lb** 

**$0.64 0.4646 lb**  **$0.64 0.4646 lb** 

**$0.08 0.0890 lb**  **# 0.0890 lb** 

**$0.08 0.0890 lb**  **$0.08 0.0890 lb** 

**# 0.0890 lb**  **$0.08**

**$0.02 0.0540 lb**  **# 0.0540 lb** 

# $0.02 **0.0540 lb $0.02**  **0.0540 lb**



# Piece Cost **Weight Piece Cost**  **Weight (Total)**

**(Total)** $0.17 0.0338 lb

**$0.03 0.0152 lb**  **# 0.0152 lb** 

**$0.03 0.0152 lb**  **$0.03 0.0152 lb** 

$0.05 0.0840 lb # 0.0840 lb

**$0.03 0.0220 lb**  **# 0.0220 lb** 

**$0.02 0.0130 lb**  **$0.02 0.0130 lb** 

$0.01 0.0090 lb $0.01 0.0090 lb

**$0.21 0.1660 lb**  **# 0.1660 lb** 

**$0.21 0.1660 lb**  **$0.21 0.1660 lb** 

**# 0.1660 lb**  **$0.21**

$0.06 0.0006 lb # 0.0006 lb

**$0.08 0.0558 lb**  **$0.08 0.0558 lb** 

**$0.01 0.0279 lb**  **# 0.0279 lb** 

**$0.08 0.0279 lb**  **# 0.0279 lb** 

**$0.08 0.0279 lb**  **$0.08 0.0279 lb** 

# Weight **Piece Cost Weight (Total)** 

**(Total) $0.03**  **0.4584 lb $0.03**  **0.4584 lb**

**$0.00 0.4576 lb**  **$0.00 0.4576 lb** 

**$0.03 0.0008 lb**  **$0.03 0.0008 lb** 

$0.06 0.0064 lb $0.06 0.0064 lb

**$0.14 0.1142 lb**  **$0.14 0.1142 lb** 

**$0.11 0.0954 lb**  **$0.11 0.0954 lb** 

**$0.11 0.0954 lb**  **# 0.0954 lb** 

**$0.11 0.0954 lb**  **$0.11 0.0954 lb** 

**# 0.0954 lb**  **$0.11**

**$0.11 0.0954 lb**  **#**

**$0.01 0.0063 lb**  **$0.01 0.0063 lb** 

**$0.01 0.0063 lb**  **# 0.0063 lb** 

**$0.01 0.0063 lb**  **$0.01 0.0063 lb** 

**$0.02 0.0125 lb**  **$0.02 0.0125 lb** 

**$0.02 0.0125 lb**  **# 0.0125 lb** 

**$0.14 0.1584 lb**  **$0.14 0.1584 lb** 



# Weight **Piece Cost Weight (Total)** 

# (Total) **$0.09 0.1016 lb**  **$0.09**

**$0.09 0.1016 lb**  **# 0.1016 lb** 

**$0.09 0.1016 lb**  **$0.09 0.1016 lb** 

**# 0.1016 lb**  **$0.09**

$0.01 0.0003 lb $0.01 0.0003 lb

$0.01 0.0001 lb $0.01 0.0001 lb

**$0.02 0.0052 lb**  **$0.02 0.0052 lb** 

**$0.02 0.0052 lb**  **# 0.0052 lb** 

**$0.02 0.0052 lb**  **$0.02 0.0052 lb** 

**$0.02 0.0512 lb**  **$0.02 0.0512 lb** 

**$0.02 0.0512 lb**  **# 0.0512 lb** 

**$0.02 0.0512 lb**  **$0.02 0.0512 lb** 

$0.23 0.1290 lb $0.23 0.1290 lb

**$4.14 2.7705 lb**  **$4.14 2.7705 lb** 

**$1.76 2.3704 lb**  **$1.76 2.3704 lb** 

**$1.76 2.3704 lb**  **$1.76 2.3704 lb** 

**$1.76 2.3704 lb**  **# 2.3704 lb** 



# Piece Cost **Weight Piece Cost**  **Weight (Total)**

**(Total) $1.39**  **2.0500 lb $1.39** 

**# 2.0500 lb**  **$1.39**

**$0.28 0.2588 lb**  **$0.28 0.2588 lb** 

# # **0.2588 lb $0.28** 

**$0.28 0.2588 lb**  **#**

$0.04 0.0308 lb $0.09 0.0616 lb

**$0.01 0.0078 lb**  **$0.01 0.0078 lb** 

**$0.01 0.0078 lb**  **$0.01 0.0078 lb** 

**$0.00 0.0276 lb**  **$0.00 0.0276 lb** 

**$0.06 0.0273 lb**  **$0.06 0.0273 lb** 

**$0.06 0.0273 lb**  **$0.06 0.0273 lb** 

$0.09 0.0038 lb $0.09 0.0038 lb

**$0.00 0.0905 lb**  **$0.00 0.0905 lb** 

**$0.05 0.0009 lb**  **$0.05 0.0009 lb** 

$0.02 0.0031 lb $0.02 0.0031 lb



# Weight **Piece Cost Weight (Total)** 

**(Total) $0.06**  **0.0273 lb $0.06**  **0.0273 lb**

**$0.06 0.0273 lb**  **$0.06 0.0273 lb** 

$0.09 0.0038 lb $0.09 0.0038 lb

**$0.00 0.0921 lb**  **$0.00 0.0921 lb** 

**$0.05 0.0009 lb**  **$0.05 0.0009 lb** 

$0.02 0.0031 lb $0.02 0.0031 lb

# $1.75 **0.0889 lb $1.75**  **0.0889 lb**

**$0.09 0.0038 lb**  **$0.09 0.0038 lb** 

$0.06 0.0006 lb $0.06 0.0006 lb

**$0.04 0.0186 lb**  **$0.04 0.0186 lb** 

**$0.04 0.0186 lb**  **$0.04 0.0186 lb** 

$0.10 0.0013 lb $0.10 0.0013 lb

**1.1500 lb $0.00**  **1.1500 lb**

**0.0180 lb $0.14**  **0.0360 lb**

**0.4400 lb $0.00**  **0.4400 lb**



# Weight **Piece Cost Weight (Total)** 

**(Total)** 

# Preassembled Totals

**Analyzed Subs:** 0

**Unanalyzed Subs:** 0

**Parts:** 0

**Fasteners:** 0 **Parts+Unanalyzed:** 0

# 10.0835 lb

**2.3340 lb**

**2.1500 lb**

**2.1500 lb**

**2.1500 lb**

0.1840 lb

**0.0146 lb**



# 0.2219 lb



# 0.2219 lb

# 0.1939 lb

**0.1939 lb**

0.0280 lb

**0.0382 lb**

**0.2750 lb**



# 0.2410 lb

**0.2410 lb**



# Weight (Total)

**0.2410 lb**

**0.0300 lb**

**0.0300 lb**

# 0.2110 lb

**0.2110 lb**

0.0340 lb

**0.0024 lb**

**0.0024 lb**

**2.9772 lb**

**0.1778 lb**

**0.1769 lb**

**0.1769 lb**



# Weight (Total)

0.0000 lb

**0.0009 lb**

**0.0009 lb**

**1.0258 lb**

**0.2550 lb**

**0.2550 lb**

# 0.4450 lb

**0.4450 lb**

**0.4450 lb**

**0.3258 lb**

**0.3258 lb**



# Weight (Total)

**0.3258 lb**

**0.3258 lb**

**0.9236 lb**

**0.9000 lb**

**0.9000 lb**

**0.9000 lb**

**0.0236 lb**

**0.0236 lb**

**0.6450 lb**

# 0.6450 lb

**0.6450 lb**

**0.2050 lb**

**0.2050 lb**



# 0.0156 lb

**0.0105 lb**

**0.0105 lb**

0.0000 lb

0.0027 lb

0.0007 lb

**0.0017 lb**

**0.0017 lb**

**0.4646 lb**

**0.0890 lb**

**0.0890 lb**

**0.0890 lb**

**0.0540 lb**

# 0.0540 lb



# 0.0338 lb

**0.0152 lb**

**0.0152 lb**

0.0840 lb

**0.0220 lb**

**0.0130 lb**

0.0090 lb

**0.1660 lb**

**0.1660 lb**

**0.1660 lb**

0.0006 lb

**0.0558 lb**

**0.0279 lb**

**0.0279 lb**

**0.0279 lb**

# 0.4584 lb

**0.4576 lb**

**0.0008 lb**

**0.0954 lb**

**0.0954 lb**

**0.0954 lb**

**0.0954 lb**

**0.0954 lb**

**0.0063 lb**

**0.0063 lb**

**0.0063 lb**

**0.0125 lb**

**0.0125 lb**

# 0.1016 lb

**0.1016 lb**

**0.1016 lb**

**0.1016 lb**

0.0003 lb

0.0001 lb

**0.0052 lb**

**0.0052 lb**

**0.0052 lb**

**0.0512 lb**

**0.0512 lb**

**0.0512 lb**



# 2.3704 lb

**2.3704 lb**



# Weight (Total)

**2.0500 lb**

**2.0500 lb**

**0.2588 lb**

# 0.2588 lb

**0.2588 lb**

0.0616 lb

**0.0078 lb**

**0.0273 lb**



# 0.0273 lb

**0.0273 lb**

# 0.0186 lb

# Assembly Report

**H Brake Booster A**

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Tool H Brake Booster First Fixture 0.0000 sec
Asm, Populated $35.51 Subassembly H Brake Booster H Brake Booster Assembly H Brake Booster 4.0000 sec
Asm, Populated Asm, Populated $35.51 Tool H Brake Booster First Fixture 0.0000 sec
Assembly $35.51 Subassembly H Brake Booster H-REAR SHELL W /PLATES H-REAR SHELL 5.0000 sec
Assembly W/ PLATES $35.51 Tool H-REAR SHELL First Fixture 0.0000 sec

W/ PLATES $42.18 Subassembly H-REAR SHELL H-REAR SHELL W /STUDS H-REAR SHELL 3.0000 sec

W/ PLATES W/ STUDS $42.18 Tool H-REAR SHELL First Fixture 0.0000 sec

W/ STUDS

- - - Spray Painted

- - $42.18 P.-P. Part H-REAR SHELL H-REAR SHELL-Press H-REAR 3.0000 sec

W/ STUDS SHELL-Press $42.18 Tool H-REAR Press 0.0000 sec

SHELL-Press $20.81 P.-P. Part H-REAR H-REAR SHELL-W ash H-REAR 3.0000 sec

SHELL-Press SHELL-W ASH $20.81 Tool H-REAR Wa sher Turbo Tunnel 0.0000 sec

SHELL-W ash

- - - In-Line W asher

- - $106.69 P.-P. Part H-REAR H-REAR SHELL, Stamping H-REAR SHELL, 3.0000 sec $106.69 P.-P. Part H-REAR SHELL, Stamping H-REAR SHELL, 3.0000 sec

SHELL-W ash Stamping $106.69 Tool H-REAR SHELL, Stamping Press 800-1k Ton 0.0000 sec Stamping $106.69 Part H-REAR SHELL, H-REAR SHELL-Material H-REAR SHELL 0.0000 sec Stamping -Material

- - - Blank weight 3.07 lbs

- -

- - - Press Size 1200 Ton &

- - Progressive

- - - Part Size after stamping (260L by

- - 260W by 92H)mm



# Design Profit ®

Page 1 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $20.81 Operation H-REAR Load Part 3.0000 sec

SHELL-W ash $20.81 Operation H-REAR Wa sh Part Medium 5.0000 sec

SHELL-W ash

# $20.81 Operation H-REAR Unload Part 2.0000 sec

SHELL-W ash $42.18 Part H-REAR H-STUD, REAR SHELL H-STUD, REAR 5.0000 sec

SHELL-Press SHELL $42.18 Fastening H-REAR Press Together 3.0000 sec

SHELL-Press $42.18 Operation H-REAR SHELL Load Part 3.0000 sec

W/ STUDS $42.18 Operation H-REAR SHELL Paint Part Medium 5.0000 sec

W/ STUDS $42.18 Operation H-REAR SHELL Unload Part 2.0000 sec

W/ STUDS

- - - G & H Seals are Identical

- - $16.39 P.-P. Part H-REAR SHELL H-VACUUM SEAL, REAR SHELL H-VACUUM 5.0000 sec

W/ PLATES SEAL, REAR
SHELL $16.39 Tool H-VACUUM Injection Molding Machine 55-150 0.0000 sec
SEAL, REAR ton
SHELL $16.39 Part H-VACUUM H-VACUUM SEAL, REAR - H-VACUUM 0.0000 sec
SEAL, REAR Material SEAL, REAR
SHELL SHELL-Material

- - - Raw Material Req 0.019 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 54mm L x 54mm W x
- - 12mm H $35.51 Fastening H-REAR SHELL Push On 2.0000 sec

W/ PLATES $35.51 Part H-REAR SHELL H-FOAM GASKET, REAR H-FOAM 5.0000 sec

W/ PLATES SHELL GASKET, REAR
SHELL $35.51 Fastening H-REAR SHELL PUSH ON 1.0000 sec

W/ PLATES $55.17 Subassembly H-REAR SHELL H-STUD PLATE, REAR SHELL H-STUD PLATE, 6.0000 sec

W/ PLATES REAR SHELL $55.17 Tool H-STUD PLATE, Anodizing Equipment 0.0000 sec

REAR SHELL 

# Design Profit ®

Page 2 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Zinc Plating, Batched Processed

- - $20.81 P.-P. Part H-STUD PLATE, H-STUD PLATE, REAR SHELL H-STUD PLATE, 3.0000 sec

REAR SHELL -W ash REAR
SHELL-W ash $20.81 Tool H-STUD PLATE, Wa sher Turbo Tunnel 0.0000 sec

REAR SHELL

-W ash

- - - In-Line W asher

- - $24.36 P.-P. Part H-STUD PLATE, H-STUD PLATE, REAR SHELL H-STUD PLATE, 3.0000 sec

REAR SHELL WE LD REAR SHELL

-W ash WE LD $24.36 Tool H-STUD PLATE, Spot W elder 0.0000 sec

REAR SHELL

# WE LD

- - - Spot-Projection W eld Auto Load

- - $15.50 P.-P. Part H-STUD PLATE, H-STUD PLATE, REAR SHELL H-STUD PLATE, 3.0000 sec

REAR SHELL STAMPED REAR SHELL

WE LD STAMPED $15.50 Tool H-STUD PLATE, Stamping Press 0-60 Ton 0.0000 sec

REAR SHELL
STAMPED $15.50 Part H-STUD PLATE, H-STUD PLATE, REAR SHELL- H-STUD PLATE, 0.0000 sec

REAR SHELL Material REAR SHELL
STAMPED -Material

- - - Blank weight 0.192 lbs

- -

- - - Press Size 60 Ton Progressive

- -

- - - Part Size after stamping (84 L by

- - 104 W by 34 H)mm $24.36 Part H-STUD PLATE, H-STUD PLATE W ASHER, H-STUD PLATE 3.0000 sec

REAR SHELL REAR SHELL WA SHER, REAR

WE LD SHELL $24.36 Fastening H-STUD PLATE, Projection W eld 3.0000 sec

REAR SHELL

WE LD $20.81 Operation H-STUD PLATE, Load Part 3.0000 sec

REAR SHELL

-W ash $20.81 Operation H-STUD PLATE, Wa sh Part Medium 5.0000 sec

REAR SHELL

-W ash



# Design Profit ®

Page 3 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $20.81 Operation H-STUD PLATE, Unload Part 2.0000 sec

REAR SHELL

-W ash $55.17 Operation H-STUD PLATE, Load Part 3.0000 sec

REAR SHELL

- - - Surface Area = 36 in^2

- - $55.17 Operation H-STUD PLATE, Electroplate Process 10.8936 sec

REAR SHELL $55.17 Operation H-STUD PLATE, Remove Part 2.0000 sec

REAR SHELL $35.51 Part H-REAR SHELL H-TINNERMAN NUT H-TINNERMAN 6.0000 sec

W/ PLATES NUT $35.51 Tool H-REAR SHELL Hand Tool 3.0000 sec

W/ PLATES $35.51 Fastening H-REAR SHELL Push On 2.0000 sec

W/ PLATES

- - - G & H FOAM SEALS ARE

- - IDENTICAL $35.51 Part H-REAR SHELL H FOAM SEAL, REAR SHELL H FOAM SEAL, 7.0000 sec

W/ PLATES REAR SHELL $35.51 Fastening H-REAR SHELL Push In Place 2.0000 sec

# W/ PLATES

$35.51 Part H-REAR SHELL H-FOAM FILTER H-FOAM FILTER 3.0000 sec

W/ PLATES $35.51 Fastening H-REAR SHELL Push In Place 2.0000 sec

W/ PLATES $28.80 P.-P. Part H-REAR SHELL H-EXCLUDER H-EXCLUDER 5.0000 sec

W/ PLATES $28.80 Tool H-EXCLUDER Injection Molding Machine 55-150 0.0000 sec

ton $28.80 Part H-EXCLUDER H-EXCLUDER, Material H-EXCLUDER, 0.0000 sec

Material

- - - Raw Material Req 0.047 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 50mm L x 58mm W x
- - 58mm H $35.51 Fastening H-REAR SHELL Push In Place 2.0000 sec

W/ PLATES $35.51 Part H-REAR SHELL H-HOSE CLAMP, EXCLUDER H-HOSE CLAMP, 5.0000 sec

W/ PLATES EXCLUDER 

# Design Profit ®

Page 4 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Fastening H-REAR SHELL Snap Together 1.0000 sec

W/ PLATES $35.51 Part H-REAR SHELL H-LOCK NUT, CLEVIS TO H-LOCK NUT, 6.0000 sec

W/ PLATES SHAFT CLEVIS TO
SHAFT $35.51 Fastening H-REAR SHELL Manual Screw 7.0000 sec

W/ PLATES $35.51 Fastening H-REAR SHELL Push In Place 2.0000 sec

W/ PLATES $35.51 P.-P. Part H-REAR SHELL H-CLEVIS TO PEDAL H-CLEVIS TO 8.0000 sec

W/ PLATES PEDAL $35.51 Tool H-CLEVIS TO First Fixture 0.0000 sec

PEDAL $16.39 P.-P. Part H-CLEVIS TO H-CLEVIS TO PEDAL, H-CLEVIS TO 3.0000 sec

PEDAL OVERMOLDED PEDAL,
OVERMOLDED $16.39 Tool H-CLEVIS TO Injection Molding Machine 55-150 0.0000 sec
PEDAL, ton
OVERMOLDED

- - - Insert Molding

- - $55.17 P.-P. Part H-CLEVIS TO H-CLEVIS TO PEDAL PLATED H-CLEVIS TO 3.0000 sec
PEDAL, PEDAL PLATED
OVERMOLDED $55.17 Tool H-CLEVIS TO Anodizing Equipment 0.0000 sec

PEDAL PLATED

- - - Zinc Plating, Batched Processed

- - $10.75 Subassembly H-CLEVIS TO H-CLEVIS TO PEDAL, W ash H-CLEVIS TO 3.0000 sec

PEDAL PLATED PEDAL, W ash $10.75 Tool H-CLEVIS TO Wa sher Duo 400 W ash Rinse & 0.0000 sec
PEDAL, W ash DRY $44.96 Subassembly H-CLEVIS TO H-CLEVIS TO PEDAL, H-CLEVIS TO 3.0000 sec

# PEDAL, W ash WE LDMENT PEDAL,

WE LDMENT $44.96 Tool H-CLEVIS TO Laser W elder 0.0000 sec
PEDAL,

WE LDMENT $15.50 P.-P. Part H-CLEVIS TO H-SUPPORT, CLEVIS TO H-SUPPORT, 3.0000 sec
PEDAL, PEDAL, Stamped CLEVIS TO

WE LDMENT PEDAL, Stamped $15.50 Tool H-SUPPORT, Stamping Press 0-60 Ton 0.0000 sec

CLEVIS TO PEDAL, Stamped 

# Design Profit ®

Page 5 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $15.50 Part H-SUPPORT, H-SUPPORT, CLEVIS TO H-SUPPORT, 0.0000 sec

CLEVIS TO PEDAL, Material CLEVIS TO PEDAL, Stamped PEDAL, Material

- - - Blank weight 0.065 lbs

- -

- - - Press Size 25 Ton Progressive

- -

- - - Part Size after stamping (34 L by

- - 14 W by 12 H)mm $42.91 P.-P. Part H-CLEVIS TO H-CLEVIS TO PEDAL STAMPED H-CLEVIS TO 3.0000 sec
PEDAL, PEDAL

WE LDMENT STAMPED $42.91 Tool H-CLEVIS TO Stamping Press 200-400 Ton 0.0000 sec

PEDAL
STAMPED $42.91 Part H-CLEVIS TO H-CLEVIS TO PEDAL, Material H-CLEVIS TO 0.0000 sec

PEDAL PEDAL, Material
STAMPED

- - - Blank weight 0.465 lbs

- -

- - - Press Size 200 Ton Progressive

- -

- - - Part Size after stamping (93 L by

- - 23 W by 30 H)mm $44.96 Tool H-CLEVIS TO Clamp 2.0000 sec
PEDAL,

WE LDMENT $44.96 Operation H-CLEVIS TO Clamp Part 3.0000 sec
PEDAL,

WE LDMENT $44.96 Fastening H-CLEVIS TO Laser W eld 1.0000 sec
PEDAL,

WE LDMENT $10.75 Operation H-CLEVIS TO Load Part 3.0000 sec
PEDAL, W ash $10.75 Operation H-CLEVIS TO Wa sh Part Medium 5.0000 sec
PEDAL, W ash $10.75 Operation H-CLEVIS TO Unload Part 2.0000 sec
PEDAL, W ash $55.17 Operation H-CLEVIS TO Load Part 3.0000 sec

PEDAL PLATED

- - - Surface Area = 13 in^2

- - $55.17 Operation H-CLEVIS TO Electroplate Process 3.9338 sec

PEDAL PLATED

# Design Profit ®

Page 6 of #

Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $55.17 Operation H-CLEVIS TO Remove Part 2.0000 sec

PEDAL PLATED $16.39 Operation H-CLEVIS TO Set In Place 1.0000 sec
PEDAL,
OVERMOLDED $16.39 Part H-CLEVIS TO H-OVERMOLD, CLEVIS TO H-OVERMOLD, 0.0000 sec
PEDAL, PEDAL, Material CLEVIS TO
OVERMOLDED PEDAL, Material

- - - Raw Material Req 0.044 lbs from

- - Cost Sheet

- - - 4 Cavity Mold

- -

- - - Box Size 93mm L x 33mm W x
- - 37mm H $16.39 P.-P. Part H-CLEVIS TO H-BUMPER, CLEVIS TO PEDAL H-BUMPER, 4.0000 sec

PEDAL CLEVIS TO

PEDAL $16.39 Tool H-BUMPER, Injection Molding Machine 55-150 0.0000 sec

CLEVIS TO ton

PEDAL $16.39 Part H-BUMPER, H-BUMPER, CLEVIS TO PEDAL, H-BUMPER, 0.0000 sec

CLEVIS TO Material CLEVIS TO

PEDAL PEDAL, Material

- - - Raw Material Req 0.002 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 10mm L x 13mm W x
- - 6mm H $35.51 Fastening H-CLEVIS TO Push In Place 2.0000 sec

PEDAL

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 7 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

# Labor **Ty pe**  **Parent Name Sy**  **mbol Name Number**  **Munro**

**Rate Score** 

- - - Space for printing

- - $35.51 Fastening H-REAR SHELL Manual Screw 7.0000 sec

W/ PLATES $35.51 Tool H-REAR SHELL Hand Tool 3.0000 sec

W/ PLATES $35.51 Fastening H-REAR SHELL Manual Screw 7.0000 sec

W/ PLATES $35.51 Operation H-REAR SHELL Part Manipulation 3.0000 sec

W/ PLATES $35.51 Subassembly H-REAR SHELL H-CENTER SECTION, H-CENTER 10.0000 sec **10.0000 sec**

W/ PLATES BOOSTER SECTION,
BOOSTER $35.51 Tool H-CENTER First Fixture 0.0000 sec
SECTION,
BOOSTER

- - - COST

- - $35.51 Subassembly H-CENTER H-PLATES & DIAPHRAGMS H-PLATES & 7.0000 sec
SECTION, DIAPHRAGMS
BOOSTER $35.51 Tool H-PLATES & First Fixture 0.0000 sec

DIAPHRAGMS $35.51 Subassembly H-PLATES & H-VALVE BODY W SEAL H-VALVE BODY 3.0000 sec

DIAPHRAGMS W SEAL $35.51 Tool H-VALVE BODY First Fixture 0.0000 sec

W SEAL $28.80 P.-P. Part H-VALVE BODY H-VALVE BODY- Molded H-VALVE 5.0000 sec

W SEAL BODY-Molded $28.80 Tool H-VALVE BODY- Injection Molding Machine 0.0000 sec

Molded 200-400 Ton $28.80 Part H-VALVE BODY- H-VALVE BODY - Material H-VALVE BODY 0.0000 sec

Molded - Material

- - - Raw Material Req 0.207 lbs from

- - Raw Material Req 0.207 lbs from

Cost Sheet

- - - 4 Cavity Mold

- -

- - - Box Size 124mm L x 57mm W x
- - 57mm H $35.51 Part H-VALVE BODY H-SEAL, VALVE BODY SQ CUT- H-SEAL, VALVE 6.0000 sec

W SEAL Molded BODY SQ
CUT-Molded



# Design Profit ®

Page 8 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $0.00 P.-P. Part H-VALVE BODY H-STAR W ASHER, VALVE H-STAR 5.0000 sec

W SEAL BODY WA SHER,
VALVE BODY $0.00 Tool H-STAR Stamping Press 0-60 Ton 0.0000 sec

WA SHER,
VALVE BODY

# $0.00 Part H-STAR H-STAR W ASHER, VALVE H-STAR 0.0000 sec

WA SHER, BODY-Material WA SHER,
VALVE BODY VALVE
BODY-Material

- - - Blank weight 0.005 lbs

- -

- - - Press Size 25 Ton & Progressive

- -

- - - Part Size after stamping (29 L by

- - 29 W by 3 H)mm $35.51 Tool H-VALVE BODY Hand Tool 3.0000 sec

W SEAL $35.51 Fastening H-VALVE BODY PUSH ON 1.0000 sec

W SEAL $35.51 Tool H-VALVE BODY Grease 6.0000 sec

W SEAL $35.51 Operation H-VALVE BODY Apply Lubricant 1.0000 sec

W SEAL $35.51 Subassembly H-PLATES & H-REAR PLATE, DIAG, CUP H-REAR PLATE, 7.0000 sec

DIAPHRAGMS DIAG, CUP $35.51 Tool H-REAR PLATE, First Fixture 0.0000 sec
DIAG, CUP $90.59 P.-P. Part H-REAR PLATE, H-REAR DIAPHRAGM-Molded H-REAR 7.0000 sec
DIAG, CUP DIAPHRAGMMolded $90.59 Tool H-REAR Inj Molding Machine 800-1500 0.0000 sec

DIAPHRAGM- Ton

Molded $90.59 Part H-REAR H-REAR DIAPHRAGM - Material H-REAR 0.0000 sec

DIAPHRAGM- DIAPHRAGM -

Molded Material

- - - Raw Material Req 0.286 lbs from

- - Cost Sheet

- - - 4 Cavity Mold

- -

- - - Box Size 254mm L x 254mm W x
- - 25mm H

- - - Space for printing

- - 

# Design Profit ®

Page 9 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Tool H-REAR PLATE, Grease 6.0000 sec
DIAG, CUP $35.51 Operation H-REAR PLATE, Apply Lubricant 1.0000 sec
DIAG, CUP $20.81 P.-P. Part H-REAR PLATE, H-REAR PLATE, CENTER H-REAR PLATE, 5.0000 sec
DIAG, CUP SECTION- W ashed CENTER
SECTIONWa shed $20.81 Tool H-REAR PLATE, Wa sher Turbo Tunnel 0.0000 sec

CENTER
SECTIONWa shed

# - - - In-Line W asher

- -

$42.91 P.-P. Part H-REAR PLATE, H-REAR PLATE, CENTER H-REAR PLATE, 5.0000 sec

CENTER SECTION- Stamping CENTER
SECTION- SECTIONWa shed Stamping $42.91 Tool H-REAR PLATE, Stamping Press 200-400 Ton 0.0000 sec

CENTER
SECTIONStamping $42.91 Part H-REAR PLATE, H-REAR PLATE, CENTER H-REAR 0.0000 sec

CENTER SECTION-Material PLATE,CENTER
SECTION- SECTION Stamping -Material

- - - Blank weight 0.983 lbs

- -

- - - Press Size 200 Ton &

- - Progressive

- - - Part Size after stamping (208 L

- - by 208W by 12 H)mm $20.81 Operation H-REAR PLATE, Load Part 3.0000 sec

CENTER
SECTIONWa shed $20.81 Operation H-REAR PLATE, Wa sh Part Medium 5.0000 sec

CENTER
SECTIONWa shed 

# Design Profit ®

Page 10 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $20.81 Operation H-REAR PLATE, Unload Part 2.0000 sec

CENTER
SECTIONWa shed

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Fastening H-REAR PLATE, Press Together 3.0000 sec
DIAG, CUP $55.17 P.-P. Part H-REAR PLATE, H-REAR CUP, CENTER H-REAR CUP, 6.0000 sec
DIAG, CUP SECTION CENTER
SECTION $55.17 Tool H-REAR CUP, Anodizing Equipment 0.0000 sec

CENTER
SECTION

- - - Zinc Plating, Batched Processed

- - $20.81 P.-P. Part H-REAR CUP, H-REAR CUP, CENTER H-REAR CUP, 3.0000 sec

CENTER SECTION-W ashed CENTER
SECTION SECTIONWa shed $20.81 Tool H-REAR CUP, Wa sher Turbo Tunnel 0.0000 sec

CENTER
SECTION-

# Wa shed

- - - In-Line W asher

- - $24.60 P.-P. Part H-REAR CUP, H-REAR CUP, CENTER H-REAR CUP, 3.0000 sec

CENTER SECTION- Stamping CENTER
SECTION- SECTIONWa shed Stamping $24.60 Tool H-REAR CUP, Stamping Press 60-200 Ton 0.0000 sec

CENTER
SECTIONStamping $24.60 Part H-REAR CUP, H-REAR CUP, CENTER H-REAR CUP, 0.0000 sec

CENTER SECTION-Material CENTER
SECTION- SECTION Stamping -Material

- - - Blank weight 0.376 lbs

- -

- - - Press Size 200 Ton &

- - Progressive 

# Design Profit ®

Page 11 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Part Size after stamping (67 L by

- - 75W by 75 H)mm $20.81 Operation H-REAR CUP, Load Part 3.0000 sec

CENTER
SECTIONWa shed $20.81 Operation H-REAR CUP, Wa sh Part Medium 5.0000 sec

CENTER
SECTIONWa shed $20.81 Operation H-REAR CUP, Unload Part 2.0000 sec

CENTER
SECTIONWa shed $55.17 Operation H-REAR CUP, Load Part 3.0000 sec

CENTER
SECTION

- - - 45 Square Inches

- - $55.17 Operation H-REAR CUP, Electroplate Process 13.6170 sec **13.6170 sec**

CENTER
SECTION $55.17 Operation H-REAR CUP, Remove Part 2.0000 sec

CENTER
SECTION

- - - LOCATE CUP OVER TABS

- - $35.51 Tool H-REAR PLATE, Press 0.0000 sec
DIAG, CUP $35.51 Material Mod. H-REAR PLATE, Bend Tab 3.0000 sec
DIAG, CUP

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

# - - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 12 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Fastening H-PLATES & Push In Place 2.0000 sec

DIAPHRAGMS $35.51 Subassembly H-PLATES & H-CENTER PLATE W SEAL H-CENTER 7.0000 sec

DIAPHRAGMS PLATE W SEAL $35.51 Tool H-CENTER First Fixture 0.0000 sec

PLATE W SEAL $20.81 P.-P. Part H-CENTER H-CENTER PLATE H-CENTER 5.0000 sec

PLATE W SEAL PLATE $20.81 Tool H-CENTER Wa sher Turbo Tunnel 0.0000 sec

PLATE

- - - In-Line W asher

- - $42.91 P.-P. Part H-CENTER H-CENTER PLATE- Stamping H-CENTER 5.0000 sec

PLATE PLATE-Stamping $42.91 Tool H-CENTER Stamping Press 200-400 Ton 0.0000 sec

PLATEStamping $42.91 Part H-CENTER H-CENTER PLATE-Material H-CENTER 0.0000 sec

PLATE- PLATE -Material Stamping

- - - Blank weight 1.617 lbs

- -

- - - Press Size 300 Ton &

- - Progressive

- - - Part Size after stamping (240 L

- - by 240W by 24 H)mm $20.81 Operation H-CENTER Load Part 3.0000 sec

PLATE $20.81 Operation H-CENTER Wa sh Part Medium 5.0000 sec

PLATE $20.81 Operation H-CENTER Unload Part 2.0000 sec

PLATE 

# Design Profit ®

Page 13 of #

# Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $16.39 P.-P. Part H-CENTER H-SEAL, CENTER PLATE- H-SEAL, 5.0000 sec

PLATE W SEAL Molded CENTER

PLATE-Molded $16.39 Tool H-SEAL, Injection Molding Machine 55-150 0.0000 sec

CENTER PLATE- ton
Molded $16.39 Part H-SEAL, H-SEAL, CENTER PLATE- H-SEAL, 0.0000 sec

CENTER PLATE- Material CENTER PLATE

Molded -Material

- - - Raw Material Req 0.03 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 76mm L x 76mm W x
- - 76mm H $35.51 Fastening H-CENTER Push In Place 2.0000 sec

PLATE W SEAL $35.51 Tool H-CENTER Grease 6.0000 sec

PLATE W SEAL $35.51 Operation H-CENTER Apply Lubricant 1.0000 sec

PLATE W SEAL

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Fastening H-PLATES & Press Together 3.0000 sec

DIAPHRAGMS $20.81 P.-P. Part H-PLATES & H-FRONT PLATE H-FRONT PLATE 3.0000 sec

DIAPHRAGMS $20.81 Tool H-FRONT PLATE Wa sher Turbo Tunnel 0.0000 sec
$24.60 P.-P. Part H-FRONT PLATE H-FRONT PLATE, Stamped H-FRONT 3.0000 sec PLATE, Stamped $24.60 Tool H-FRONT Stamping Press 60-200 Ton 0.0000 sec PLATE, Stamped $24.60 Part H-FRONT H-FRONT PLATE BLANK H-FRONT PLATE 0.0000 sec PLATE, Stamped BLANK

- - - Blank weight 1.17 lbs

- -

- - - Press Size 200 Ton &

- - Progressive



# Design Profit ®

Page 14 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Part Size after stamping (220 L

- - by 220W by 20 H)mm

- - - In-Line W asher

- -

# $20.81 Operation H-FRONT PLATE Load Part 3.0000 sec

$20.81 Operation H-FRONT PLATE Wa sh Part Medium 5.0000 sec
$20.81 Operation H-FRONT PLATE Unload Part 2.0000 sec

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Fastening H-PLATES & PUSH ON 1.0000 sec

DIAPHRAGMS $35.51 Tool H-PLATES & Grease 6.0000 sec

DIAPHRAGMS $35.51 Operation H-PLATES & Apply Lubricant 1.0000 sec

DIAPHRAGMS $90.59 P.-P. Part H-PLATES & H-CENTER DIAPHRAGM- H-CENTER 7.0000 sec

DIAPHRAGMS Molded DIAPHRAGMMolded $90.59 Tool H-CENTER Inj Molding Machine 800-1500 0.0000 sec

DIAPHRAGM- Ton

Molded $90.59 Part H-CENTER H-CENTER DIAPHRAGM - H-CENTER 0.0000 sec

DIAPHRAGM- Material DIAPHRAGM

Molded -Material

- - - Raw Material Req 0.232 lbs from

- - Cost Sheet

- - - 4 Cavity Mold

- -

- - - Box Size 220mm L x 220mm W x
- - 45mm H $35.51 Fastening H-PLATES & Press Together 3.0000 sec

DIAPHRAGMS

- - - INPUT SIDE PHOTO

- - $35.51 Fastening H-CENTER Push In Place 2.0000 sec
SECTION,
BOOSTER $35.51 Subassembly H-CENTER H-C0NNECTOR, INPUT ROD TO H-C0NNECTOR, 6.0000 sec
SECTION, SOLENOID INPUT ROD TO
BOOSTER SOLENOID $35.51 Tool H-C0NNECTOR, First Fixture 0.0000 sec

INPUT ROD TO
SOLENOID 

# Design Profit ®

Page 15 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $16.39 P.-P. Part H-C0NNECTOR, H-HOUSING, CONNECTOR- H-HOUSING, 5.0000 sec

INPUT ROD TO Molded CONNECTORSOLENOID Molded $16.39 Tool H-HOUSING, Injection Molding Machine 55-150 0.0000 sec

CONNECTOR- ton
Molded $16.39 Part H-HOUSING, H-HOUSING, CONNECTOR - H-HOUSING, 0.0000 sec

CONNECTOR- Material CONNECTOR -

Molded Material

- - - Raw Material Req 0.016 lbs from

- - Cost Sheet

- - - 4 Cavity Mold

- -

# - - - Box Size 55mm L x 28mm W x
- - 28mm H $35.51 Part H-C0NNECTOR, H-SEAL, CONNECTOR- Molded H-SEAL, 6.0000 sec

INPUT ROD TO CONNECTORSOLENOID Molded $35.51 Fastening H-C0NNECTOR, Push In Place 2.0000 sec

INPUT ROD TO
SOLENOID $35.51 Part H-C0NNECTOR, H-W AVE W ASHER, H-W AVE 5.0000 sec

INPUT ROD TO CONNECTOR WA SHER,
SOLENOID CONNECTOR

- - - STAINLESS STEEL W ASHER

- - $35.51 Part H-C0NNECTOR, H-W ASHER, CONNECTOR H-W ASHER, 6.0000 sec

INPUT ROD TO CONNECTOR
SOLENOID $16.39 P.-P. Part H-C0NNECTOR, H-RETAINER, CONNECTOR- H-RETAINER, 6.0000 sec

INPUT ROD TO Molded CONNECTORSOLENOID Molded $16.39 Tool H-RETAINER, Injection Molding Machine 55-150 0.0000 sec

CONNECTOR- ton
Molded $16.39 Part H-RETAINER, H-RETAINER, CONNECTOR H-RETAINER, 0.0000 sec

CONNECTOR- -Material CONNECTOR

Molded -Material

- - - Raw Material Req 0.003 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 25mm L x 25mm W x
- - 11.6mm H



# Design Profit ®

Page 16 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Fastening H-C0NNECTOR, Snap Together 1.0000 sec

INPUT ROD TO
SOLENOID

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

# - - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 17 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Subassembly H-CENTER H-INPUT ROD ASSEMBLY H-INPUT ROD 5.0000 sec
SECTION, ASSEMBLY
BOOSTER $35.51 Tool H-INPUT ROD First Fixture 0.0000 sec

ASSEMBLY

- - - G & H RODS ARE THE SAME

- - $10.75 P.-P. Part H-INPUT ROD H-INPUT ROD, VALVE BODY H-INPUT ROD, 5.0000 sec

ASSEMBLY VALVE BODY

- - - "W ashing, Small Size and/or Low

- - Complexity" $10.75 Tool H-INPUT ROD, Wa sher Duo 400 W ash Rinse & 0.0000 sec

VALVE BODY DRY $20.90 P.-P. Part H-INPUT ROD, H-INPUT ROD, VALVE H-INPUT ROD, 3.0000 sec

VALVE BODY BODY-Machined VALVE
BODY-Machined

- - - CNC Turning 1.75" Bar 2 Axis

- - $20.90 Tool H-INPUT ROD, CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec

VALVE bar
BODY-Machined

- - - Includes Bar Feeder

- - $20.90 Part H-INPUT ROD, H-INPUT ROD, VALVE H-INPUT ROD, 0.0000 sec

VALVE BODY-Material VALVE
BODY-Machined BODY-Material

- - - Bar stock weight 0.15 lbs.

- -

- - - Box size of finished part 10Dmm

- -

# x 93Lmm

$20.90 Operation H-INPUT ROD, Load Part 3.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Clamp Part 3.0000 sec

VALVE
BODY-Machined



# Design Profit ®

Page 18 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $20.90 Material Mod. H-INPUT ROD, Turn End face 1-30mm 2.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Auto Tool Change 5.0000 sec

VALVE
BODY-Machined $20.90 Material Mod. H-INPUT ROD, Turn OD Contoured surface fins 5.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Unclamp Part 1.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Part Manipulation 3.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Clamp Part 3.0000 sec

VALVE
BODY-Machined $20.90 Material Mod. H-INPUT ROD, Turn End face 1-30mm 2.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Auto Tool Change 5.0000 sec

VALVE
BODY-Machined $20.90 Material Mod. H-INPUT ROD, Turn Threads 2.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Unclamp Part 1.0000 sec

VALVE
BODY-Machined $20.90 Operation H-INPUT ROD, Unload Part 2.0000 sec

VALVE
BODY-Machined

- - - Batch Type W asher

- -

- - - 5-10 min cycle time

- -

- - - Basket Size 15.75x18.50x25.50

- - inches x 2 $10.75 Operation H-INPUT ROD, Load Part 3.0000 sec

VALVE BODY $10.75 Operation H-INPUT ROD, Wa sh Part Medium 5.0000 sec

VALVE BODY

# Design Profit ®

Page 19 of #

Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $10.75 Operation H-INPUT ROD, Unload Part 2.0000 sec

VALVE BODY $15.50 P.-P. Part H-INPUT ROD H-RETAINER, INPUT ROD H-RETAINER, 5.0000 sec

ASSEMBLY SPRING INPUT ROD
SPRING $15.50 Tool H-RETAINER, Stamping Press 0-60 Ton 0.0000 sec

INPUT ROD
SPRING $15.50 Part H-RETAINER, H-RETAINER, INPUT ROD H-RETAINER, 0.0000 sec

INPUT ROD SPRING-Material INPUT ROD
SPRING SPRING-Material

- - - Blank weight 0.018 lbs

- -

- - - Press Size 25 Ton & Progressive

- -

- - - Part Size after stamping (30 L by

- - 30 W by 6 H)mm

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Part H-INPUT ROD H-SPRING, INPUT ROD H-SPRING, 4.0000 sec

ASSEMBLY INPUT ROD $16.39 P.-P. Part H-INPUT ROD H-RETAINER, POPPET SPRING H-RETAINER, 3.0000 sec

ASSEMBLY WI TH SEAL POPPET
SPRING W ITH
SEAL $16.39 Tool H-RETAINER, Injection Molding Machine 55-150 0.0000 sec

POPPET ton
SPRING W ITH
SEAL $16.39 Part H-RETAINER, H-RETAINER, POPPET SPRING H-RETAINER, 0.0000 sec

POPPET WI TH SEAL-Material POPPET SPRIN
SPRING W ITH WI TH
SEAL SEAL-Material

- - - Raw Material Req 0.021 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 36mm L x 36mm W x
- - 19mm H

- - - Space for printing

- - 

# Design Profit ®

Page 20 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

# Rate **Score**

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Part H-INPUT ROD H-SPRING, POPPET VALVE H-SPRING, 6.0000 sec

ASSEMBLY POPPET VALVE $16.39 P.-P. Part H-INPUT ROD H-POPPET, VALVE BODY H-POPPET, 2.0000 sec

ASSEMBLY VALVE BODY $16.39 Tool H-POPPET, Injection Molding Machine 55-150 0.0000 sec

VALVE BODY ton

- - - INSERT MOLDING

- -

- - - G & H W ASHER ARE SAME

- - $16.39 Part H-POPPET, H-W ASHER, POPPET, VALVE H-W ASHER, 3.0000 sec

VALVE BODY BODY-Material POPPET, VALVE
BODY $16.39 Fastening H-POPPET, Set In Place 1.0000 sec

VALVE BODY $16.39 Part H-POPPET, H-POPPET, VALVE H-POPPET, 0.0000 sec

VALVE BODY BODY-Material VALVE
BODY-Material

- - - Raw Material Req 0.013 lbs from

- - Cost Sheet

- - - 8 Cavity Mold

- -

- - - Box Size 30mm L x 30mm W x
- - 13mm H

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 21 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Fastening H-INPUT ROD COMPRESS SPRINGS 3.0000 sec

# ASSEMBLY

$10.75 P.-P. Part H-INPUT ROD H-PLUNGER VALVE BODY H-PLUNGER 5.0000 sec

ASSEMBLY VALVE BODY $10.75 Tool H-PLUNGER Wa sher Duo 400 W ash Rinse & 0.0000 sec

VALVE BODY DRY $20.90 P.-P. Part H-PLUNGER H-PLUNGER VALVE BODY H-PLUNGER 2.0000 sec

VALVE BODY VALVE
BODY-Machined $20.90 Tool H-PLUNGER CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec

VALVE BODY bar

- - - Includes Bar Feeder

- - $20.90 Part H-PLUNGER H-PLUNGER, VALVE BODY H-PLUNGER, 0.0000 sec

VALVE BODY BAR STOCK VALVE BODY
BAR STOCK

- - - Bar stock weight 0.38 lbs.

- -

- - - Box size of finished part 20Dmm

- - x 52Lmm $20.90 Material Mod. H-PLUNGER Turn end face 1-30mm 2.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Auto Tool Change 5.0000 sec

VALVE BODY $20.90 Material Mod. H-PLUNGER Turn OD 30-60mm 2.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Auto Tool Change 5.0000 sec

VALVE BODY $20.90 Material Mod. H-PLUNGER Turn OD Contoured surface fins 5.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Auto Tool Change 5.0000 sec

VALVE BODY $20.90 Material Mod. H-PLUNGER Drill & Chamfer Hole 1-30mm 1.0000 sec

VALVE BODY 

# Design Profit ®

Page 22 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $20.90 Operation H-PLUNGER Auto Tool Change 5.0000 sec

VALVE BODY $20.90 Material Mod. H-PLUNGER Tap Hole 0.5000 sec

VALVE BODY $20.90 Operation H-PLUNGER Unclamp Part 1.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Part Manipulation 3.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Clamp Part 3.0000 sec

VALVE BODY $20.90 Material Mod. H-PLUNGER Turn end face 1-30mm 2.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Auto Tool Change 5.0000 sec

VALVE BODY $20.90 Material Mod. H-PLUNGER Drill & Chamfer Hole 1-30mm 1.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Auto Tool Change 5.0000 sec

VALVE BODY $20.90 Material Mod. H-PLUNGER Bore Hole 1-30mm 1.0000 sec

VALVE BODY

# $20.90 Operation H-PLUNGER Unclamp Part 1.0000 sec

VALVE BODY $20.90 Operation H-PLUNGER Unload Part 2.0000 sec

VALVE BODY

- - - Batch Type W asher

- -

- - - 5-10 min cycle time

- -

- - - Basket Size 15.75x18.50x25.50

- - inches x 2 $10.75 Operation H-PLUNGER Load Part 3.0000 sec

VALVE BODY $10.75 Operation H-PLUNGER Wa sh Part Medium 5.0000 sec

VALVE BODY $10.75 Operation H-PLUNGER Unload Part 2.0000 sec

VALVE BODY $35.51 Operation H-INPUT ROD CDI 1.0000 sec

ASSEMBLY $35.51 Tool H-INPUT ROD Special Tool 6.0000 sec

ASSEMBLY $35.51 Fastening H-INPUT ROD Gross Deform 5.0000 sec

ASSEMBLY

- - - G & H SEALS ARE THE SAME

- - 

# Design Profit ®

Page 23 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Part H-INPUT ROD H SEAL, POPPET VALVE H SEAL, 2.0000 sec

ASSEMBLY POPPET VALVE $35.51 Tool H-INPUT ROD Grease 6.0000 sec

ASSEMBLY $35.51 Fastening H-INPUT ROD APPLY GREASE 5.0000 sec

ASSEMBLY $35.51 Operation H-CENTER CDI 1.0000 sec
SECTION,
BOOSTER

- - - G & H KEYS ARE THE SAME

- - $16.39 P.-P. Part H-CENTER H KEY, BOOSTER H KEY, 6.0000 sec
SECTION, BOOSTER
BOOSTER $16.39 Tool H KEY, Injection Molding Machine 55-150 0.0000 sec

BOOSTER ton

- - - INSERT MOLDING

- - $16.39 Part H KEY, H KEY, BOOSTER-Material H KEY, 0.0000 sec

BOOSTER BOOSTERMaterial $16.39 Fastening H KEY, Set In Place 1.0000 sec

BOOSTER $15.50 P.-P. Part H KEY, H Metal KEY, BOOSTER H Metal KEY, 3.0000 sec

BOOSTER BOOSTER $15.50 Tool H Metal KEY, Stamping Press 0-60 Ton 0.0000 sec

BOOSTER $15.50 Part H Metal KEY, H Metal KEY, H Metal KEY, 0.0000 sec

BOOSTER BOOSTER-Material BOOSTERMaterial

- - - Blank weight 0.103 lbs

- -

# - - - Press Size 60 Ton & Progressive

- -

- - - Part Size after stamping (54 L by

- - 20 W by 4 H)mm

- - - Raw Material Req 0.006 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 54mm L x 20mm W x
- - 4mm H $35.51 Fastening H-CENTER PUSH ON 1.0000 sec
SECTION,
BOOSTER



# Design Profit ®

Page 24 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Subassembly H-REAR SHELL H Solenoid w Seal, Booster H Solenoid w 7.0000 sec

W/ PLATES Seal, Booster $35.51 Tool H Solenoid w First Fixture 0.0000 sec
Seal, Booster $29.69 Subassembly H Solenoid w H Solenoid, Booster H Solenoid, 4.0000 sec
Seal, Booster Booster $35.51 Part H Solenoid w H Lip Seal, Booster, Solenoid H Lip Seal, 6.0000 sec
Seal, Booster Booster, Solenoid $35.51 Fastening H Solenoid w Push In Place 2.0000 sec
Seal, Booster $35.51 Tool H Solenoid w Grease 6.0000 sec
Seal, Booster $35.51 Operation H Solenoid w Apply Lubricant 1.0000 sec
Seal, Booster $35.51 Part H-REAR SHELL H Screw, Solenoid to Shaft H Screw, 6.0000 sec

W/ PLATES Solenoid to Shaft $35.51 Tool H-REAR SHELL Power Tool 4.0000 sec

W/ PLATES $35.51 Fastening H-REAR SHELL Power Screw 4.0000 sec

W/ PLATES $35.51 Subassembly H-REAR SHELL H-REACTION DISK ASSEMBLY H-REACTION 5.0000 sec

W/ PLATES DISK
ASSEMBLY $35.51 Tool H-REACTION First Fixture 0.0000 sec

DISK
ASSEMBLY $10.75 P.-P. Part H-REACTION H Retainer, Reaction Disc H Retainer, 5.0000 sec

DISK Reaction Disc
ASSEMBLY $10.75 Tool H Retainer, Wa sher Duo 400 W ash Rinse & 0.0000 sec

Reaction Disc DRY $41.20 P.-P. Part H Retainer, H Retainer, Reaction Disc, H Retainer, 3.0000 sec

Reaction Disc Machined Reaction Disc,

Machined $41.20 Tool H Retainer, EC-300-ML Horizontal CNC 0.0000 sec
Reaction Disc, Machine

Machined $43.52 P.-P. Part H Retainer, H Retainer, Reaction Disc, H Retainer, 3.0000 sec
Reaction Disc, Trimed Reaction Disc,

# Machined Trimed



# Design Profit ®

Page 25 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $43.52 Tool H Retainer, Trim Press 0.0000 sec
Reaction Disc,

Trimed $70.80 P.-P. Part H Retainer, H Retainer, Reaction Disc, Die H Retainer, 3.0000 sec
Reaction Disc, Cast Reaction Disc,

Trimed Die Cast $70.80 Tool H Retainer, Die Casting 0 - 500 ton 0.0000 sec
Reaction Disc,
Die Cast $70.80 Part H Retainer, H Retainer, Reaction Disc, H Retainer, 0.0000 sec
Reaction Disc, Material Reaction Disc,
Die Cast Material

- - - Raw Material Req 0.10 lbs from

- - Cost Sheet

- - - 12 Cavity Mold

- -

- - - Box Size 57mm L x 52mm W x
- - 33mm H $41.20 Operation H Retainer, Load Part 3.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Clamp Part 3.0000 sec
Reaction Disc,

Machined $41.20 Material Mod. H Retainer, Drill Hole 1.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Unclamp Part 1.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Part Manipulation 3.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Clamp Part 3.0000 sec
Reaction Disc,

Machined $41.20 Material Mod. H Retainer, Drill & Chamfer Hole 1-30mm 1.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Auto Tool Change 5.0000 sec
Reaction Disc,

Machined



# Design Profit ®

Page 26 of # Copyright 2005© Munro & Associates, Inc.

# H Brake Booster A **sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $41.20 Material Mod. H Retainer, Turn End face 1-30mm 2.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Auto Tool Change 5.0000 sec
Reaction Disc,

Machined $41.20 Material Mod. H Retainer, Chamfer OD sml 1.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Auto Tool Change 5.0000 sec
Reaction Disc,

Machined $41.20 Material Mod. H Retainer, Cut Groove sml 2.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Unclamp Part 1.0000 sec
Reaction Disc,

Machined $41.20 Operation H Retainer, Unload Part 2.0000 sec
Reaction Disc,

Machined $10.75 Operation H Retainer, Load Part 3.0000 sec

Reaction Disc $10.75 Operation H Retainer, Wa sh Part Medium 5.0000 sec

Reaction Disc $10.75 Operation H Retainer, Unload Part 2.0000 sec

Reaction Disc

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - Space for printing

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 27 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $10.75 P.-P. Part H-REACTION H Piston, Reaction Disc H Piston, 4.0000 sec

# DISK Reaction Disc
ASSEMBLY $10.75 Tool H Piston, Wa sher Duo 400 W ash Rinse & 0.0000 sec

Reaction Disc DRY $20.90 P.-P. Part H Piston, H Piston, Reaction Disc, Turned H Piston, 4.0000 sec

Reaction Disc Reaction Disc,

Turned $20.90 Tool H Piston, CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec
Reaction Disc, bar

Turned

- - - Includes Bar Feeder

- - $20.90 Part H Piston, H Piston, Reaction Disc, Material H Piston, 0.0000 sec
Reaction Disc, Reaction Disc,

Turned Material

- - - Bar stock weight 0.02 lbs.

- -

- - - Box size of finished part 11mm D

- - x 5.6mm L

- - - Turn Face & Max OD (11mm)

- - $20.90 Material Mod. H Piston, Turn End face 1-30mm 2.0000 sec
Reaction Disc,

Turned $20.90 Operation H Piston, Reposition Cutting Tool 2.0000 sec
Reaction Disc,

Turned $20.90 Material Mod. H Piston, Turn OD 1-30mm 1.0000 sec
Reaction Disc,

Turned

- - - Turn Undercut OD (6.2mm)

- - $20.90 Operation H Piston, Auto Tool Change 5.0000 sec
Reaction Disc,

Turned $20.90 Material Mod. H Piston, Turn OD 1-30mm 1.0000 sec
Reaction Disc,

Turned



# Design Profit ®

Page 28 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $20.90 Operation H Piston, Reposition Cutting Tool 2.0000 sec
Reaction Disc,

Turned

- - - Face End & Bevel

- - $20.90 Material Mod. H Piston, Turn End face 1-30mm 2.0000 sec
Reaction Disc,

Turned $20.90 Operation H Piston, Reposition Cutting Tool 2.0000 sec
Reaction Disc,

Turned $20.90 Material Mod. H Piston, Chamfer OD sml 1.0000 sec
Reaction Disc,

Turned

- - - Cut Off & Unload

- - $20.90 Operation H Piston, Auto Tool Change 5.0000 sec

# Reaction Disc,

Turned $20.90 Material Mod. H Piston, Cut to Length 1.0000 sec
Reaction Disc,

Turned $20.90 Operation H Piston, Unload Part 2.0000 sec
Reaction Disc,

Turned $10.75 Operation H Piston, Load Part 3.0000 sec

Reaction Disc $10.75 Operation H Piston, Wa sh Part Medium 5.0000 sec

Reaction Disc $10.75 Operation H Piston, Unload Part 2.0000 sec

Reaction Disc

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $16.39 P.-P. Part H-REACTION H Reaction Disc H Reaction Disc 5.0000 sec

DISK
ASSEMBLY $16.39 Tool H Reaction Disc Injection Molding Machine 55-150 0.0000 sec

ton $16.39 Part H Reaction Disc H Reaction Disc, Material H Reaction Disc, 0.0000 sec

Material 

# Design Profit ®

Page 29 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Raw Material Req 0.017 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

- - - Box Size 34mm L x 34mm W x
- - 6mm H $35.51 Fastening H-REACTION Push In Place 2.0000 sec

DISK
ASSEMBLY $35.51 Subassembly H-REAR SHELL H Output Rod Assembly H Output Rod 5.0000 sec

W/ PLATES Assembly $35.51 Tool H Output Rod First Fixture 0.0000 sec
Assembly

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

# - - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 30 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $10.75 P.-P. Part H Output Rod H Rod Output H Rod Output 3.0000 sec
Assembly $10.75 Tool H Rod Output Wa sher Duo 400 W ash Rinse & 0.0000 sec

DRY $21.43 P.-P. Part H Rod Output H Rod Output, Machined H Rod Output, 3.0000 sec

Machined $21.43 Tool H Rod Output, CNC Turning 2 Axis SL-10, Odd 0.0000 sec

Machined Form $115.72 P.-P. Part H Rod Output, H Output Rod, Forged H Output Rod, 3.0000 sec

Machined Forged $115.72 Tool H Output Rod, Forging Press 500 Ton 0.0000 sec
Forged $115.72 Part H Output Rod, H Output Rod, Material H Output Rod, 0.0000 sec
Forged Material

- - - Raw Material Req 0.112 lbs

- -

- - - Box Size 42mm L x 34mm W x
- - 34mm H

- - - One hit based on rough - near net

- - shape $115.72 Material Mod. H Output Rod, Forge 500T 0.8500 sec
Forged $21.43 Operation H Rod Output, Clamp Part 3.0000 sec

Machined

- - - Face End End & Turn Max OD

- - $21.43 Material Mod. H Rod Output, Turn I/D 30-60 mm 1.0000 sec

Machined $21.43 Operation H Rod Output, Reposition Cutting Tool 2.0000 sec

Machined $21.43 Material Mod. H Rod Output, Turn End Face 30-60mm 4.0000 sec

Machined

- - - Grab Turned Piece with 2nd

- - Chuck Head $21.43 Operation H Rod Output, Unclamp Part 1.0000 sec

Machined $21.43 Operation H Rod Output, Part Manipulation 3.0000 sec

Machined

# $21.43 Operation H Rod Output, Clamp Part 3.0000 sec

Machined

- - - Face End End & Turn Min OD

- - $21.43 Material Mod. H Rod Output, Turn End face 1-30mm 2.0000 sec

Machined 

# Design Profit ®

Page 31 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $21.43 Operation H Rod Output, Reposition Cutting Tool 2.0000 sec

Machined $21.43 Material Mod. H Rod Output, Turn OD 1-30mm 1.0000 sec

Machined

- - - Bevel Face & Drill Hole

- - $21.43 Operation H Rod Output, Reposition Cutting Tool 2.0000 sec

Machined $21.43 Material Mod. H Rod Output, Chamfer OD sml 1.0000 sec

Machined $21.43 Operation H Rod Output, Auto Tool Change 5.0000 sec

Machined $21.43 Material Mod. H Rod Output, Drill & Chamfer Hole 1-30mm 1.0000 sec

Machined $21.43 Operation H Rod Output, Unclamp Part 1.0000 sec

Machined $21.43 Operation H Rod Output, Unload Part 2.0000 sec

Machined $10.75 Operation H Rod Output Load Part 3.0000 sec
$10.75 Operation H Rod Output Wa sh Part Medium 5.0000 sec
$10.75 Operation H Rod Output Unload Part 2.0000 sec

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 32 of # Copyright 2005© Munro & Associates, Inc.

# H Brake Booster A **sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Part H Output Rod H W asher, Output Rod, 0.59 mm H W asher, 6.0000 sec
Assembly Output Rod, 0.59

mm $35.51 Part H Output Rod H W asher, Output Rod, 0.10 mm H W asher, 6.0000 sec
Assembly Output Rod, 0.10

mm $10.75 P.-P. Part H Output Rod H Socket, Output Rod H Socket, Output 6.0000 sec
Assembly Rod $10.75 Tool H Socket, Output Wa sher Duo 400 W ash Rinse & 0.0000 sec

Rod DRY $42.68 P.-P. Part H Socket, Output H Socket, Output Rod, Machined H Socket, Output 3.0000 sec

Rod Rod, Machined $42.68 Tool H Socket, Output CNC TL-15 4 Axis Twin Spindle 0.0000 sec
Rod, Machined Lathe - Auto Load

- - - Includes Bar Feeder

- - $42.68 Part H Socket, Output H Socket, Output Rod, Material H Socket, Output 0.0000 sec
Rod, Machined Rod, Material

- - - Bar stock weight 0.02 lbs.

- -

- - - Box size of finished part 7mm D x

- - 17mm L

- - - Turn Ball End & Max OD (7mm)

- - $42.68 Material Mod. H Socket, Output Milled face 1.0000 sec
Rod, Machined $42.68 Operation H Socket, Output Reposition Cutting Tool 2.0000 sec
Rod, Machined $42.68 Material Mod. H Socket, Output Turn OD 1-30mm 1.0000 sec
Rod, Machined

- - - Grab Turned Piece with 2nd

- - Chuck Head $42.68 Operation H Socket, Output Auto Tool Change 5.0000 sec
Rod, Machined $42.68 Material Mod. H Socket, Output Cut to Length 1.0000 sec
Rod, Machined

- - - Turn Undercut OD (3mm)

- - $42.68 Operation H Socket, Output Auto Tool Change 5.0000 sec
Rod, Machined $42.68 Material Mod. H Socket, Output Turn OD 1-30mm 1.0000 sec
Rod, Machined



# Design Profit ®

Page 33 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $42.68 Operation H Socket, Output Reposition Cutting Tool 2.0000 sec
Rod, Machined

- - - Face End & Cut Groove

- - $42.68 Material Mod. H Socket, Output Turn End face 1-30mm 2.0000 sec

# Rod, Machined

$42.68 Operation H Socket, Output Auto Tool Change 5.0000 sec
Rod, Machined $42.68 Material Mod. H Socket, Output Cut slot 1.0000 sec
Rod, Machined $42.68 Operation H Socket, Output Unclamp Part 1.0000 sec
Rod, Machined $42.68 Operation H Socket, Output Unload Part 2.0000 sec
Rod, Machined $10.75 Operation H Socket, Output Load Part 3.0000 sec

Rod $10.75 Operation H Socket, Output Wa sh Part Medium 5.0000 sec

Rod $10.75 Operation H Socket, Output Unload Part 2.0000 sec

Rod

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - Space for printing 

# Design Profit ®

Page 34 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Fastening H Output Rod Push In Place 2.0000 sec
Assembly $10.75 P.-P. Part H Output Rod H Retainer, Output Rod H Retainer, 5.0000 sec
Assembly Output Rod $10.75 Tool H Retainer, Wa sher Duo 400 W ash Rinse & 0.0000 sec Output Rod DRY $15.50 P.-P. Part H Retainer, H Retainer, Output Rod, Stamped H Retainer, 3.0000 sec Output Rod Output Rod, Stamped $15.50 Tool H Retainer, Stamping Press 0-60 Ton 0.0000 sec Output Rod, Stamped

# $15.50 Part H Retainer, H Retainer, Output Rod, Material H Retainer, 0.0000 sec Output Rod, Output Rod, Stamped Material

- - - Blank weight 0.046 lbs

- -

- - - Press Size 25 Ton Progressive

- -

- - - Part Size after stamping (48 L by

- - 48 W by25 H)mm $10.75 Operation H Retainer, Load Part 3.0000 sec Output Rod $10.75 Operation H Retainer, Wa sh Part Medium 5.0000 sec Output Rod $10.75 Operation H Retainer, Unload Part 2.0000 sec Output Rod $35.51 Tool H Output Rod Grease 6.0000 sec
Assembly $35.51 Operation H Output Rod Apply Lubricant 1.0000 sec
Assembly

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 35 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

# - - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 36 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $35.51 Part H Brake Booster H Spring Large, Brake Booster H Spring Large, 6.0000 sec
Assembly Brake Booster

- - - Front Shell Outside

- - $35.51 Subassembly H Brake Booster H Front Shell Asm, Brake Booster H Front Shell 6.0000 sec
Assembly Asm, Brake

Booster $35.51 Tool H Front Shell First Fixture 0.0000 sec
Asm, Brake

Booster

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

# - - - Space for printing

- -



# Design Profit ®

Page 37 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - 

# Design Profit ®

Page 38 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Space for printing

- -

# - - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- -

- - - Space for printing

- - $42.18 Subassembly H Front Shell H Front Shell Asm, Painted H Front Shell 2.0000 sec
Asm, Brake Asm, Painted

Booster $42.18 Tool H Front Shell First Fixture 0.0000 sec
Asm, Painted

- - - Spray Painted

- - $20.81 P.-P. Part H Front Shell H Front Shell Asm, W ashed H Front Shell 3.0000 sec
Asm, Painted Asm, W ashed $20.81 Tool H Front Shell Wa sher Turbo Tunnel 0.0000 sec
Asm, W ashed

- - - In-Line W asher

- - $42.18 P.-P. Part H Front Shell H Front Shell Asm, Pressed H Front Shell 3.0000 sec
Asm, W ashed Together Asm, Pressed Together $42.18 Tool H Front Shell Press 0.0000 sec
Asm, Pressed Together $141.76 P.-P. Part H Front Shell H Front Shell Outer, Stamped H Front Shell 3.0000 sec
Asm, Pressed Outer, Stamped Together $141.76 Tool H Front Shell Stamping Press 1k-1.5k Ton 0.0000 sec Outer, Stamped $141.76 Part H Front Shell H Front Shell, Material H Front Shell, 0.0000 sec $141.76 H Front Shell H Front Shell, Material H Front Shell, 0.0000 sec Outer, Stamped Material

- - - Blank weight 3.099 lbs

- -

- - - Press Size 1001 Ton Progressive

- - 

# Design Profit ®

Page 39 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Part Size after stamping (243 L

- - by 24 W by 60 H)mm $42.18 P.-P. Part H Front Shell H Stud Plate, Front Shell, H Stud Plate, 8.0000 sec
Asm, Pressed Engraved Front Shell, Together Engraved $42.18 Tool H Stud Plate, Label Engraver 0.0000 sec
Front Shell, Engraved $15.50 P.-P. Part H Stud Plate, H Stud Plate, Front Shell, H Stud Plate, 8.0000 sec
Front Shell, Stamped Front Shell, Engraved Stamped $15.50 Tool H Stud Plate, Stamping Press 0-60 Ton 0.0000 sec

# Front Shell, Stamped $15.50 Part H Stud Plate, H Stud Plate, Front Shell, H Stud Plate, 0.0000 sec
Front Shell, Material Front Shell, Stamped Material

- - - Blank weight 0.615 lbs

- -

- - - Press Size 60 Ton Progressive

- -

- - - Part Size after stamping (130 L

- - by 57 W by 6 H)mm

- - - Engrave 6 Characters at 0.5

- - sec/each $42.18 Material Mod. H Stud Plate, Engrave 4.0000 sec
Front Shell, Engraved $42.18 Operation H Front Shell Set In Place 1.0000 sec
Asm, Pressed Together $42.18 Part H Front Shell H-Stud Short, Front Shell H-Stud Short, 5.0000 sec
Asm, Pressed Front Shell Together $42.18 Operation H Front Shell Set In Place 1.0000 sec
Asm, Pressed Together $42.18 Fastening H Front Shell Press Together 3.0000 sec
Asm, Pressed Together $20.81 Operation H Front Shell Load Part 3.0000 sec
Asm, W ashed $20.81 Operation H Front Shell Wa sh Part Medium 5.0000 sec
Asm, W ashed 

# Design Profit ®

Page 40 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $20.81 Operation H Front Shell Unload Part 2.0000 sec
Asm, W ashed $42.18 Operation H Front Shell Load Part 3.0000 sec
Asm, Painted $42.18 Operation H Front Shell Paint Part Medium 5.0000 sec
Asm, Painted $42.18 Operation H Front Shell Unload Part 2.0000 sec
Asm, Painted

- - - Photo of Inside

- -

- - - G & H Seals are Identical

- - $16.39 P.-P. Part H Front Shell H Vacuum Hose Seal, Front Shell H Vacuum Hose 6.0000 sec
Asm, Brake Seal, Front Shell

Booster $16.39 Tool H Vacuum Hose Injection Molding Machine 55-150 0.0000 sec
Seal, Front Shell ton $16.39 Part H Vacuum Hose H Vacuum Hose Seal, Front H Vacuum Hose 0.0000 sec
Seal, Front Shell Shell, Material Seal, Front Shell,

Material

- - - Raw Material Req 0.011 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- -

# - - - Box Size 28mm L x 28mm W x
- - 10mm H $35.51 Fastening H Front Shell Push In Place 2.0000 sec
Asm, Brake

Booster

- - - Check Valve in G Shell = Valve in

- - H Hose $35.51 Subassembly H Front Shell H Vacuum Hose Fitting, Front H Vacuum Hose 5.0000 sec
Asm, Brake Shell Fitting, Front

Booster Shell $35.51 Tool H Vacuum Hose First Fixture 0.0000 sec
Fitting, Front
Shell

- - - Injection Molding, Vibration W eld

- - $35.51 Fastening H Front Shell Push In Place 2.0000 sec
Asm, Brake

Booster

- - - Sensors Aranged &

- - Photographed

- - - Position Sensor

- - 

# Design Profit ®

Page 41 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $16.39 P.-P. Part H Front Shell H Retainer, Front Shell H Retainer, Front 5.0000 sec
Asm, Brake Shell

Booster $16.39 Tool H Retainer, Front Injection Molding Machine 55-150 0.0000 sec

Shell ton $16.39 Part H Retainer, Front Shell, Material 0.0000 sec Shell ton $16.39 Part H Retainer, Front H Retainer, Front Shell, Material H Retainer, Front 0.0000 sec

Shell Shell, Material

- - - Raw Material Req 0.035 lbs from

- - Cost Sheet

- - - 4 Cavity Mold

- -

- - - Box Size 43mm L x 42mm W x
- - 33mm H $35.51 Tool H Front Shell Grease 6.0000 sec
Asm, Brake

Booster $35.51 Operation H Front Shell Apply Lubricant 1.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H O-Ring, Retainer, Front Shell H O-Ring, 6.0000 sec
Asm, Brake Retainer, Front

Booster Shell $35.51 Fastening H Front Shell Push On 2.0000 sec
Asm, Brake

Booster $35.51 Fastening H Front Shell Push In Place 2.0000 sec
Asm, Brake

Booster $35.51 Subassembly H Front Shell H Position Sensor, Front Shell H Position 5.0000 sec
Asm, Brake Sensor, Front

Booster Shell $35.51 Tool H Front Shell Grease 6.0000 sec

# Asm, Brake

Booster $35.51 Operation H Front Shell Apply Lubricant 1.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H O-Ring, Sensor, Front Shell H O-Ring, 5.0000 sec
Asm, Brake Sensor, Front

Booster Shell $35.51 Fastening H Front Shell Push On 2.0000 sec
Asm, Brake

Booster 

# Design Profit ®

Page 42 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Fastening H Front Shell Push In Place 2.0000 sec
Asm, Brake

Booster $35.51 Operation H Front Shell CDI 1.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H C-Clip, Front Shell H C-Clip, Front 6.0000 sec
Asm, Brake Shell

Booster $35.51 Tool H Front Shell Hand Tool 3.0000 sec
Asm, Brake

Booster $35.51 Fastening H Front Shell Snap Together 1.0000 sec
Asm, Brake

Booster $16.39 P.-P. Part H Front Shell H Retainer, Front Shell H Retainer, Front 5.0000 sec
Asm, Brake Shell

Booster $16.39 Tool H Retainer, Front Injection Molding Machine 55-150 0.0000 sec

Shell ton $16.39 Part H Retainer, Front H Retainer, Front Shell, Material H Retainer, Front 0.0000 sec

Shell Shell, Material

- - - Raw Material Req 0.035 lbs from

- - Cost Sheet

- - - 4 Cavity Mold

- -

- - - Box Size 43mm L x 42mm W x
- - 33mm H $35.51 Tool H Front Shell Grease 6.0000 sec
Asm, Brake

Booster $35.51 Operation H Front Shell Apply Lubricant 1.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H O-Ring, Retainer, Front Shell H O-Ring, 6.0000 sec
Asm, Brake Retainer, Front

Booster Shell $35.51 Fastening H Front Shell Push On 2.0000 sec
Asm, Brake

Booster $35.51 Fastening H Front Shell Push In Place 2.0000 sec
Asm, Brake

# Booster



# Design Profit ®

Page 43 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score** 

- - - Pressure Sensor

- - $35.51 Subassembly H Front Shell H Pressure Sensor, Front Shell H Pressure 5.0000 sec
Asm, Brake Sensor, Front

Booster Shell $35.51 Tool H Front Shell Grease 6.0000 sec
Asm, Brake

Booster $35.51 Operation H Front Shell Apply Lubricant 1.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H O-Ring, Sensor, Front Shell H O-Ring, 5.0000 sec
Asm, Brake Sensor, Front

Booster Shell $35.51 Fastening H Front Shell Push On 2.0000 sec
Asm, Brake

Booster $35.51 Fastening H Front Shell Push In Place 2.0000 sec
Asm, Brake

Booster $35.51 Operation H Front Shell CDI 1.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H C-Clip, Front Shell H C-Clip, Front 6.0000 sec
Asm, Brake Shell

Booster $35.51 Tool H Front Shell Hand Tool 3.0000 sec
Asm, Brake

Booster $35.51 Fastening H Front Shell Snap Together 1.0000 sec
Asm, Brake

Booster

- - - Electrical Harness

- -

- - - Turn Shell Over

- - $35.51 Operation H Front Shell Part Manipulation 3.0000 sec
Asm, Brake

Booster $35.51 Subassembly H Front Shell H Electrical Harness, Front Shell H Electrical 6.0000 sec
Asm, Brake Harness, Front

Booster Shell $35.51 Tool H Front Shell Grease 6.0000 sec
Asm, Brake

Booster 

# Design Profit ®

Page 44 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

# Labor **Ty pe**  **Parent Name Sy**  **mbol Name Number**  **Munro**

**Rate Score**  $35.51 Operation H Front Shell Apply Lubricant 1.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H O-Ring, Retainer, Front Shell H O-Ring, 6.0000 sec
Asm, Brake Retainer, Front

Booster Shell $35.51 Fastening H Front Shell Push On 2.0000 sec
Asm, Brake

Booster $35.51 Part H Front Shell H O-Ring, Retainer Small, Front H O-Ring, 5.0000 sec
Asm, Brake Shell Retainer Small,

Booster Front Shell $35.51 Fastening H Front Shell Push On 2.0000 sec
Asm, Brake

Booster $35.51 Fastening H Front Shell Push On 2.0000 sec
Asm, Brake

Booster $35.51 Operation H Front Shell Part Manipulation 3.0000 sec
Asm, Brake

Booster $16.39 P.-P. Part H Front Shell H Harness Retainer, Front Shell H Harness 4.0000 sec
Asm, Brake Retainer, Front

Booster Shell $16.39 Tool H Harness Injection Molding Machine 55-150 0.0000 sec
Retainer, Front ton
Shell $16.39 Part H Harness H Harness Retainer, Front Shell, H Harness 0.0000 sec **12.8350 sec**
Retainer, Front Material Retainer, Front
Shell Shell, Material

- - - Raw Material Req 0.025 lbs from

- - Cost Sheet

- - - 10 Cavity Mold

- - 10 Cavity Mold

- - - Box Size 43mm L x 43mm W x
- - 13.5mm H $35.51 Fastening H Front Shell Press Together 3.0000 sec
Asm, Brake

Booster

- - - Harness in Place

- - $35.51 Part H Brake Booster H Label, Brake Booster, Front H Label, Brake 6.0000 sec
Assembly Shell Booster, Front
Shell 

# Design Profit ®

Page 45 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Operation H Brake Booster Peel Off Adhesive Backing 4.0000 sec
Assembly $35.51 Fastening H Brake Booster Apply Label 3.0000 sec
Assembly $35.51 Multitouch H Brake Booster G Front Shell, Brake Booster G Front Shell, 8.0000 sec
Assembly Harness, Regrab Brake Booster

# Harness, Regrab

$35.51 Operation H Brake Booster CDI 1.0000 sec
Assembly $35.51 Fastening H Brake Booster Push in Electrical Connector 2.0000 sec
Assembly $35.51 Operation H Brake Booster CDI 1.0000 sec
Assembly $35.51 Multitouch H Brake Booster H Front Shell, Brake Booster, H Front Shell 11.0000 sec **11.0000 sec** Assembly Regrab Asm, Brake

Booster $35.51 Tool H Brake Booster Special Tool 0.0000 sec
Assembly $35.51 Fastening H Brake Booster Crimp tabs 1.0000 sec
Assembly

- - - G & H Master Cylinder are

- - Almost Identical $35.51 Subassembly H Brake Booster H MASTER CYLINDER H MASTER 4.0000 sec
Asm, Populated CYLINDER $35.51 Tool H MASTER First Fixture 0.0000 sec

CYLINDER $35.51 Part H Brake Booster H Nut, Cylinder to Booster H Nut, Cylinder to 6.0000 sec
Asm, Populated Booster $35.51 Tool H Brake Booster Power Tool 4.0000 sec
Asm, Populated $35.51 Fastening H Brake Booster Power Screw 4.0000 sec
Asm, Populated $35.51 Tool H Brake Booster Paint Marker 2.0000 sec
Asm, Populated $35.51 Operation H Brake Booster Mark Part 3.0000 sec
Asm, Populated $35.51 Subassembly H Brake Booster H Vacuum Hose, Booster H Vacuum Hose, 5.0000 sec
Asm, Populated Booster $35.51 Tool H Vacuum Hose, First Fixture 0.0000 sec

Booster

- - - Hoses & check valve are

- - different, should we cost? 

# Design Profit ®

Page 46 of # Copyright 2005© Munro & Associates, Inc.



# H Brake Booster A

**sm, Populated**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro** 

**Rate Score**  $35.51 Fastening H Brake Booster Push Tube in place 3.0000 sec
Asm, Populated $35.51 Tool H Brake Booster Hand Tool 3.0000 sec
Asm, Populated $35.51 Fastening H Brake Booster Position Clamp 2.0000 sec
Asm, Populated $35.51 Tool H Brake Booster Paint Marker 2.0000 sec
Asm, Populated $35.51 Operation H Brake Booster Mark Part 3.0000 sec
Asm, Populated 

# Report Totals **Count:** ##

# Design Profit ®

Page 47 of #

Copyright 2005© Munro & Associates, Inc.

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

0.0000 sec $0.00 $0.00 1 $0.00

4.0000 sec

- $0.04 1

-

0.0000 sec $0.00 $0.00 1 $0.00

5.0000 sec

- $0.05 1

-

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec

- $0.03 1

-

0.0000 sec $0.00 $0.00 1 $0.00

- - - - - 3.0000 sec

- $0.04 1

-

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec

- $0.04 1

-

0.0000 sec $0.00 $0.00 1 $0.00

- - - - - 3.0000 sec

- $0.02 1

-



# 0.0000 sec $0.00 $0.00 1 $0.00

**7.5000 sec** $1.38 $0.22 1 $1.38

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**3.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

# 2.0000 sec $0.00 $0.01 1 $0.00

**5.0000 sec** $0.06 $0.06 4 $0.25

**3.0000 sec** $0.00 $0.04 4 $0.00

**3.0000 sec** $0.00 $0.04 1 $0.00

**5.0000 sec** $0.00 $0.06 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**-** - - - - **5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**2.3810 sec** $0.04 $0.01 1 $0.04

**-** - - - -

**-** - - - -

**-** - - - -

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.08 $0.05 1 $0.08

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec**

- $0.06 1

-



# 0.0000 sec $0.00 $0.00 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - - **3.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **3.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

# - - - - -

**3.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**0.7000 sec** $0.10 $0.00 1 $0.10

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.01 $0.02 4 $0.03

**3.0000 sec** $0.00 $0.02 4 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.05 1 $0.00

**-** - - - - **1.8156 sec** $0.00 $0.03 1 $0.00

**2.0000 sec** $0.00 $0.03 1 $0.00

**6.0000 sec** $0.01 $0.06 4 $0.04

**3.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 4 $0.00

**-** - - - -

**7.0000 sec** $0.06 $0.07 1 $0.06

**2.0000 sec** $0.00 $0.02 1 $0.00

# 3.0000 sec $0.06 $0.03 1 $0.06

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**1.4590 sec** $0.06 $0.01 1 $0.06

**-** - - - -

**-** - - - -

**-** - - - -

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.05 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.05 $0.06 1 $0.05

**7.0000 sec** $0.00 $0.07 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**8.0000 sec**

- $0.08 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.03 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **3.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **3.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.01 1

-

# 0.0000 sec $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.04 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**0.6000 sec** $0.04 $0.00 1 $0.04

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec**

- $0.04 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**1.7000 sec** $0.22 $0.02 1 $0.22

**-** - - - -

**-** - - - -

**-** - - - -

**2.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.04 1 $0.00

**1.0000 sec** $0.00 $0.01 2 $0.00

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.05 1 $0.00

**-** - - - - **1.8156 sec** $0.00 $0.03 1 $0.00

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.00 1 $0.00

**3.0500 sec** $0.05 $0.01 1 $0.05

**-** - - - -

**-** - - - -

**-** - - - -

**4.0000 sec**

- $0.04 2

-

**0.0000 sec** $0.00 $0.00 2 $0.00

**4.8250 sec** $0.01 $0.02 2 $0.01

**-** - - - -

**-** - - - -

**-** - - - -

**2.0000 sec** $0.00 $0.02 2 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - - **7.0000 sec** $0.00 $0.07 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**7.0000 sec** $0.00 $0.07 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**10.0000 sec**

- $0.10 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **7.0000 sec**

- $0.07 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.03 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**5.1140 sec** $0.25 $0.04 1 $0.25

**-** - - - -



# - - - - -

**-** - - - -

**6.0000 sec** $0.06 $0.06 1 $0.06



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

# 0.6000 sec $0.01 $0.00 1 $0.01

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**7.0000 sec**

- $0.07 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**7.0000 sec**

- $0.07 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**4.2500 sec** $0.31 $0.11 1 $0.31

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

# - - - - -

**5.0000 sec**

- $0.03 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**1.7000 sec** $0.45 $0.02 1 $0.45

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **3.0000 sec** $0.00 $0.03 1 $0.00

**6.0000 sec**

- $0.06 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **3.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

# - - - - -

**3.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**1.7000 sec** $0.17 $0.01 1 $0.17

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**3.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.05 1 $0.00

**-** - - - - **13.6170 sec** $0.00 $0.21 1 $0.00

**2.0000 sec** $0.00 $0.03 1 $0.00

**-** - - - - **0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **2.0000 sec** $0.00 $0.02 1 $0.00

**7.0000 sec**

- $0.07 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **5.0000 sec**

- $0.03 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**1.8000 sec** $0.74 $0.02 1 $0.74

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.2300 sec** $0.04 $0.01 1 $0.04

**-** - - - -

**-** - - - -

**-** - - - -

**2.0000 sec** $0.00 $0.02 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **3.0000 sec** $0.00 $0.03 1 $0.00

**3.0000 sec**

- $0.03 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**1.7000 sec** $0.66 $0.01 1 $0.66

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

# 3.0000 sec $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - - **1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**7.0000 sec**

- $0.07 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**2.1800 sec** $0.25 $0.05 1 $0.25

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.03 1 $0.00

**-** - - - - **2.0000 sec** $0.00 $0.02 1 $0.00

**6.0000 sec**

- $0.06 1

-



# 0.0000 sec $0.00 $0.00 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**2.5220 sec** $0.10 $0.01 1 $0.10

**-** - - - -

**-** - - - -

# - - - - -

**6.0000 sec** $0.06 $0.06 1 $0.06

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.09 $0.05 1 $0.09

**-** - - - - **6.0000 sec** $0.01 $0.06 1 $0.01

**6.0000 sec**

- $0.06 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**0.9330 sec** $0.02 $0.00 1 $0.02

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **5.0000 sec**

- $0.05 1

-

**-** - - - -

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.01 1

-

**-** - - - - **0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **0.0000 sec** $0.08 $0.00 1 $0.08

**-** - - - -

**-** - - - -

# 3.0000 sec $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**0.6000 sec** $0.02 $0.00 1 $0.02

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **4.0000 sec** $0.17 $0.04 1 $0.17

**3.0000 sec**

- $0.03 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**0.9900 sec** $0.03 $0.00 1 $0.03

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

# Cost **(Total) (Total)** 

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **6.0000 sec** $0.05 $0.06 1 $0.05

**2.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - -

**-** - - - - **3.0000 sec** $0.02 $0.01 1 $0.02

**1.0000 sec** $0.00 $0.00 1 $0.00

**0.9870 sec** $0.01 $0.00 1 $0.01

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **3.0000 sec** $0.00 $0.03 1 $0.00

# 5.0000 sec

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**2.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **0.0000 sec** $0.21 $0.00 1 $0.21

**-** - - - -

**-** - - - -

**2.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**5.0000 sec** $0.00 $0.03 1 $0.00

**0.5000 sec** $0.00 $0.00 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

# 1.0000 sec $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

**5.0000 sec** $0.00 $0.05 1 $0.00

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**0.6530 sec** $0.06 $0.01 1 $0.06

**6.0000 sec** $0.00 $0.06 1 $0.00

**5.0000 sec** $0.00 $0.05 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - - **6.0000 sec**

- $0.06 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **0.7620 sec** $0.01 $0.00 1 $0.01

**1.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**0.7000 sec** $0.08 $0.00 1 $0.08

**-** - - - -

# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**1.0000 sec** $0.00 $0.01 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**7.0000 sec**

- $0.07 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**4.0000 sec** $0.00 $0.04 1 $0.00

**6.0000 sec** $0.03 $0.06 1 $0.03

**2.0000 sec** $0.00 $0.02 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.06 $0.06 1 $0.06

**4.0000 sec** $0.00 $0.04 1 $0.00

**4.0000 sec** $0.00 $0.04 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.03 1

-

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**0.0000 sec** $0.00 $0.00 1 $0.00

**6.1800 sec**

- $0.07 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**2.9000 sec** $0.11 $0.06 1 $0.11

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.03 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.06 1 $0.00

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.06 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **4.0000 sec**

- $0.04 1

-

# 0.0000 sec $0.00 $0.00 1 $0.00

**4.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **0.0000 sec** $0.01 $0.00 1 $0.01

**-** - - - -

**-** - - - -

**-** - - - - **2.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - - **5.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - - **2.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - - **5.0000 sec** $0.00 $0.03 1 $0.00

# 1.0000 sec $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**8.0460 sec** $0.02 $0.04 1 $0.02



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**3.0000 sec**

- $0.03 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**0.0000 sec** $0.09 $0.00 1 $0.09

**-** - - - -

**-** - - - -

**-** - - - -

**0.8500 sec** $0.00 $0.03 1 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

**-** - - - - **1.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**4.0000 sec** $0.00 $0.02 1 $0.00

**-** - - - -

**1.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

# 3.0000 sec $0.00 $0.02 1 $0.00

**-** - - - - **2.0000 sec** $0.00 $0.01 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - - **2.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - - **6.0000 sec** $0.01 $0.06 1 $0.01

**6.0000 sec** $0.01 $0.06 1 $0.01

**6.0000 sec**

- $0.06 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **0.0000 sec** $0.02 $0.00 1 $0.02

**-** - - - -

**-** - - - -

**-** - - - - **1.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -



# 5.0000 sec $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - - **5.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.02 1 $0.00

**-** - - - - **2.0000 sec** $0.00 $0.02 1 $0.00

# 5.0000 sec $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - - **2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.01 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

# 0.6000 sec $0.02 $0.00 1 $0.02

**-** - - - -

**-** - - - -

**-** - - - -

**3.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - - **6.0000 sec** $0.23 $0.06 1 $0.23

**-** - - - - **6.0000 sec**

- $0.06 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

# - - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

# - - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - - **2.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **3.0000 sec**

- $0.04 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **3.0000 sec**

- $0.02 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0000 sec**

- $0.04 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**7.3000 sec** $1.39 $0.29 1 $1.39



# - - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - -

**8.0000 sec**

- $0.09 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**8.0000 sec**

- $0.09 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

# 0.7000 sec $0.28 $0.00 1 $0.28

**-** - - - -

**-** - - - -

**-** - - - -

**-** - - - -

**6.0000 sec** $0.00 $0.07 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.04 $0.06 2 $0.09

**1.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.04 2 $0.00

**3.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.03 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.01 1 $0.00

**3.0000 sec** $0.00 $0.04 1 $0.00

**5.0000 sec** $0.00 $0.06 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**-** - - - -

**-** - - - - **6.0000 sec**

- $0.06 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**3.0200 sec** $0.01 $0.01 1 $0.01

**-** - - - -

**-** - - - -

# - - - - -

**2.0000 sec** $0.00 $0.02 1 $0.00

**-** - - - -

**5.0000 sec** $0.00 $0.05 1 $0.00

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - - **2.0000 sec** $0.00 $0.02 1 $0.00

**-** - - - -

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**9.4450 sec** $0.06 $0.04 1 $0.06

**-** - - - -

**-** - - - -

**-** - - - -

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.09 $0.06 1 $0.09

**2.0000 sec** $0.00 $0.02 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.00 $0.05 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

# 1.0000 sec $0.00 $0.01 1 $0.00

**5.0000 sec** $0.05 $0.05 1 $0.05

**2.0000 sec** $0.00 $0.02 1 $0.00



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**2.0000 sec** $0.00 $0.02 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.02 $0.06 1 $0.02

**3.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec**

- $0.05 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**9.4450 sec** $0.06 $0.04 1 $0.06

**-** - - - -

**-** - - - -

**-** - - - -

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.09 $0.06 1 $0.09

**2.0000 sec** $0.00 $0.02 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**-** - - - - **5.0000 sec** $0.00 $0.05 1 $0.00

**6.0000 sec** $0.00 $0.06 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**5.0000 sec** $0.05 $0.05 1 $0.05

**2.0000 sec** $0.00 $0.02 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.02 $0.06 1 $0.02

**3.0000 sec** $0.00 $0.03 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**-** - - - -

**-** - - - - **3.0000 sec** $0.00 $0.03 1 $0.00

**6.0000 sec** $1.75 $0.06 1 $1.75

**6.0000 sec** $0.00 $0.06 1 $0.00

# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**1.0000 sec** $0.00 $0.01 1 $0.00

**6.0000 sec** $0.09 $0.06 1 $0.09

**2.0000 sec** $0.00 $0.02 1 $0.00

**5.0000 sec** $0.06 $0.05 1 $0.06

**2.0000 sec** $0.00 $0.02 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**4.0000 sec**

- $0.04 1

-

**0.0000 sec** $0.00 $0.00 1 $0.00

**12.8350 sec** $0.04 $0.06 1 $0.04

**-** - - - -

**-** - - - -



# - - - - -

**3.0000 sec** $0.00 $0.03 1 $0.00

**-** - - - - **6.0000 sec** $0.10 $0.06 1 $0.10



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**4.0000 sec** $0.00 $0.04 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**8.0000 sec** $0.00 $0.08 1 $0.00

# 1.0000 sec $0.00 $0.01 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**1.0000 sec** $0.00 $0.01 1 $0.00

**11.0000 sec** $0.00 $0.11 1 $0.00

**0.0000 sec** $0.00 $0.00 1 $0.00

**1.0000 sec** $0.00 $0.01 16 $0.00

**-** - - - -

**4.0000 sec** $0.00 $0.04 1 $0.00

**0.0000 sec** $0.00 $0.00 1 $0.00

**6.0000 sec** $0.07 $0.06 2 $0.14

**4.0000 sec** $0.00 $0.04 1 $0.00

**4.0000 sec** $0.00 $0.04 2 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.03 2 $0.00

**5.0000 sec** $0.00 $0.05 1 $0.00

**0.0000 sec** $0.00 $0.00 1 $0.00

**-** - - - -



# Actual Time **Piece Cost Total Labor**  **Qty Piece Cost** 

**Cost (Total)**  **(Total)**

**3.0000 sec** $0.00 $0.03 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**2.0000 sec** $0.00 $0.02 1 $0.00

**3.0000 sec** $0.00 $0.03 1 $0.00

**548 $11.36** 

# H Brake Booster A **ssembly , Populated**  **Part # QTY** 

x **H-BRA KE BOOSTER A**  **SSEMBLY, POPULA**

**TED** 

# 1

x H-MASTER CYLINDER ASM 

# 1

x H-NUT, CYLINDER TO BOOSTER 

# 2

x H-VACUUM HOSE, BOOSTER 

# 1

x A **H-BRA KE BOOSTER A**  **SSEMBLY** 

# 1

x H-SPRING, LARGE BRAKE BOOSTER 

# 1

x H-LABEL, BRAKE BOOSTER, FRONT SHELL 

# 1

x B **H-REA R SHELL W/PLA**  **TES** 

# 1

x H-VACUUM SEAL, REAR 

# 1

x H-FOAM GASKET, REAR 

# 1

x H-TINNERMAN NUT 

# 4

x H FOAM SEAL, REAR SHELL 

# 1

x H-FOAM FILTER 

# 1

x H-EXCLUDER 

# 1

x H-HOSE CLAMP, EXCLUDER 

# 1

x H-LOCK NUT, CLEVIS TO SHAFT 

# 1

x H- SCREW , SOLENOID TO SHAFT 

# 1

x B1 **H-REA R SHELL W/STUDS**  

# 1

x H- REAR SHELL, STAMPED 

# 1

x H-STUD, REAR SHELL 

# 4

x B2 **H-STUD PLA TE, REA**  **R SHELL** 

# 1

x H-STUD PLATE, STAMPED 

# 1

x H-STUD PLATE W ASHER, REAR SHELL 

# 4

x B3 **H-CLEVIS TO PEDA L**  

# 1

x H-BUMPER, CLEVIS TO PEDAL 

# 2

x B3A **H-SUPPORT,CLEVIS TO PEDA L PLA**  **TED** 

# 1

x H-SUPPORT,CLEVIS TO PEDAL 

# 1

x H-CLEVIS TO PEDAL,STAMPED 

# 1

x B4 **H-CENTER SECTION, BOOSTER** 

# 1

x B4A **H-PLA TES & DIA**  **PHRA GMS**  

# 1

x H-FRONT PLATE 

# 1

x H-CENTER DIAPHRAGM,MOLDED 

# 1

x B4A1 **H-VA LVE BODY W SEA**  **L** 

# 1

x H-VALVE BODY,MOLDED 

# 1

x H - VALVE BODY SQ CUT, MOLDED 

# 1

x H- STAR W ASHER, VALVE BODY 

# 1

x B4A2 **H-REA R PLA**  **TE, DIA G. CUP**  

# 1

x H-REAR DIAPHRAGM,MOLDED 

# 1

x H-REAR PLATE,CENTER SECTION 

# 1

x H-REAR CUP,CENTER SECTION 

# 1

x B4A3 **H-CENTER PLA TE W SEA**  **L** 

# 1

x H-CENTER PLATE 

# 1

x H SEAL,CENTER PLATE 

# 1

x B4B **H-CONNECTER,INPUT ROD TO SOLENOID** 

# 1

x H-HOUSING CONNECTER, SOLENOID 

# 1

x H-SEAL CONNECTER, SOLENOID 

# 1

# x H-W AVE W ASHER, CONNECTER 

# 1

x H- W ASHER, CONNECTER 

# 1

x H-RETAINER CONNECTER 

# 1

x B4C **H-INPUT ROD A SSEMBLY**  

# 1

x H-INPUT ROD VALVE, BODY 

# 1

x H-RETAINER INPUT ROD SPRING 

# 1

x H-SPRING, INPUT ROD 

# 1

x H-RETAINER POPPET SPRING 

# 1

x H- SPRING, POPPET VALVE 

# 1

x H-POPPET VALVE BODY 

# 1

x H-W ASHER, POPPET VALVE BODY 

# 1

x H-PLUNGER, VALVE BODY 

# 1

x H-SEAL, POPPET VALVE 

# 1

x B4D **H- KEY, BOOSTER** 

# 1

x H-KEY BOOSTER, MATE 

# 1

x H- KEY, BOOSTER, METAL 

# 1

x B5 **H- REA CTION DISK A**  **SSEMBLY** 

# 1

x H-RETAINER, REACTION DISK 

# 1

x H-PISTON, REACTION DISK 

# 1

x H-REACTION DISK 

# 1

x B6 **H-OUTPUT ROD A SSEMBLY**  

# 1

x H-ROD OUTPUT 

# 1

x H-W ASHER, OUTPUT ROD .59 

# 1

x H-W ASHER, OUTPUT ROD .10 

# 1

x H-SOCKET, OUTPUT ROD 

# 1

x H-RETAINER, OUTPUT ROD 

# 1

x B7 **H-SOLENOID W SEA L, BOOSTER**  

# 1

x H-SOLENOID, BOOSTER 

# 1

x H- LIP SEAL, SOLENOID BOOSTER 

# 1

x C **H-FRONT SHELL A SSEMBLY, BRA**  **KE BOOSTER** 

# 1

x H-VACUUM HOSE SEAL,FRONT SHELL 

# 1

x H-VACUUM HOSE FITTING, FRONT SHELL 

# 1

x H-RETAINER,FRONT SHELL 

# 1

x H-O RING, RETAINER,FRONT SHELL 

# 1

x H-POSITION SENSOR, FRONT SHELL 

# 1

x H-O RING SENSOR,FRONT SHELL 

# 1

x H-C CLIP, FRONT SHELL 

# 1

x H-RETAINER, FRONT SHELL 

# 1

x H-O RING, RETAINER,FRONT SHELL 

# 1

x H-PRESSURE SENSOR, FRONT SHELL 

# 1

x H-O RING SENSOR,FRONT SHELL 

# 1

x H-C CLIP, FRONT SHELL 

# 1

x H-ELECTRICAL HARNESS, FRONT SHELL 

# 1

x H-O RING, RETAINER,FRONT SHELL 

# 1

x H-O RING, RETAINER,SMALL,FRONT SHELL 

# 1

x H-HARNESS RETAINER, FRONT SHELL 

# 1

x C1 **H-FRONT SHELL A SSEMBLY, PA**  **INTED** 

# 1

x H- FRONT SHELL, STAMPED 

# 1

x H-STUD PLATE, FRONT SHELL 

# 1

x H- STUD SHORT,FRONT SHELL 

# 2

# Total 108

# $$$ **Comments**

0.94 Out of Scope

0.16 Commodity

1.44

1.12

0.26 Commodity

0.12 Commodity

2.63

0.08

0.10 Commodity

0.04 Commodity

0.07 Commodity

0.07 Commodity

0.14

0.11 Commodity Pricing?

0.06 Commodity

0.07 Commodity

0.37

2.11

0.28 Commodity

1.57

0.11

0.03 Commodity

0.15

0.22

1.18

0.05

0.30

0.67

0.11

0.76

0.71

0.21

0.55

0.07 Commodity

0.01 Commodity

0.23

0.62

0.68

0.35

0.14

1.02

0.11

0.36

0.18

0.06 Commodity

# 0.11 Commodity

0.01 Commodity

0.05

0.58

0.67

0.03

0.20 Commodity

0.05

0.06 Commodity

0.14

0.02 Commodity

1.06

0.07 Commodity

Overmold

0.12

0.10

0.12

1.14

0.43

0.21

0.37

1.00

0.005

0.005

0.60

0.05

0.17

12.35 Commodity Pricing?

0.03 Commodity

2.73

0.09

0.38 Commodity Pricing?

0.28

0.10 Commodity

6.17 Commodity Pricing?

0.06 Commodity

0.02 Commodity

0.28

0.10 Commodity

9.06 Commodity Pricing?

0.06 Commodity

0.02 Commodity

2.02 Commodity

0.10 Commodity

0.07 Commodity

0.33

0.35

1.99

0.44

0.10 Commodity

# 65.12

# Includes Tier1I/OEM markup Used: **T1 Moderate Assembly Complexity**

Assumed returnable dunnage - no dividers Used: **Returnable Dunnage**

Input Rod Assembly - material PET-GF36 not in RM database -Used Lean Design ~$1.20/lb (See Input Rod assembly tab)

# H- Brake Booster Assemby

**Sensors & Solenoid**

**Position Sensor** ATE 10.6518-9077.1 8L17

Mass: 0.0905 Asm

Components: Material Mass (lb) Comments Estimated Cost Source

Housing PA6-GF30 0.0582 Molded in 3 pin Connector Housing (Unsealed) 0.17 FEV Cost Model

Base PA6-GF30 0.0028 0.04 FEV Cost Model Shaft retainer, molded PA6-GF30 0.004 0.04 FEV Cost Model Spring Steel - 1008 0.0019 0.05 Commodity

Shaft Steel - SS 0.0102 Machined 0.31 FEV Cost Model Shaft - Molded cap/base PA66 ?? 0.002 0.04 FEV Cost Model Carrier, Wiper Contact PA66 ?? 0.0018 0.04 FEV Cost Model

Board 0.0086 helag PP-S 013 548 8 10 1.00 Commodity Sealing compound 0.0008 0.03 Commodity

Connector hardware Mass included in Housing 0.15 Commodity Wiper contact 0.0008 Estimate Mass included in carrier 0.10 Commodity

0.0903 0.0002

Shaft Assembly 0.75 FEV Cost Model Sensor Assembly 2.49 FEV Cost Model T1 Mark Up 0.91 FEV Cost Model

Estimated Cost 6.12

# Pressure Sensor ATE

Mass 0.0921 Asm

Components: Material Mass (lb) Comments Estimated Cost

Housing PPE-PA-GF30 0.0635 0.0501 Molded in 4 pin Connector Housing 0.15 FEV Cost Model Cap PPE-PA-GF30 0.0073 0.0073 0.05 FEV Cost Model

Side Cover PPE-PA-GF30 0.0007 0.0007 0.04 FEV Cost Model

Board 0.0016 0.0032 2 semiconductor Melexis 2.00 Commodity $1.00

Ceramic Plate 0.0036 0.0072 2 Board/sensor are a purchased Melixis system 1.50 Commodity $0.75 o-ring 0.0002 0.0004 2 0.02 Commodity $0.01 board/ceramic plate housing Steel - SS 0.0075 0.015 2 0.05 FEV Cost Model $0.025 board/ceramic plate cap Steel - SS 0.0035 0.007 2 0.03 FEV Cost Model $0.015 ceramic plate/o-ring frame PA66 ?? 0.0005 0.001 2 0.03 FEV Cost Model $0.015

Connector Hardware 1 0.15 Commodity

Adhesive 0.03 Commodity

0.0919 0.0002

Board /Sensor Assembly 1.25 Sensor Assembly 2.50 T1 Mark Up 1.20

Estimated Cost 9.00

# Solenoid, Booster

Mass 0.4572 Asm

Components: Material Mass (lb) Comments Estimated Cost

Housing Steel - SS 0.1589 2.29 FEV Cost Model Cap Steel - SS 0.08 Estimate 1.65 FEV Cost Model

Connector 0.05 Estimate Five pin unsealed connector PIA cap 1.50 Commodity

Coil 0.1135 Estimate PIA cap 1.75 Commodity Relay Valve Piston MC-Steel-1018, Bar 

# 0.0532 0.56 FEV Cost Model

Seal- inner 0.0004 0.03 Commodity Brass Insert - Relay Valve Piston 0.0005 0.02 Commodity Brass Insert - Relay Valve Piston 0.0005 0.02 Commodity

0.457 0.0002

Relay Valve Assembly 0.36 Solenoid assembly 2.49 T1 Mark Up 1.64

Estimated Cost 12.31

### Page: 1 of 6 

# 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: Wire Harness Connector - Vacuum Sensor Brake Booster**  

## Part Number: **060760-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 

**Rate $/Hour**  **(DB) Burden** 

**Rate $/Hour**  **(DB) Applied** 

**Burden**

**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**

**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 Wire Harness Connector - Vacuum Sensor

Brake Booster 060760-N0502-01 **1 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**

**0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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)**

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**



### 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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  **$0.00 $0.00**  **$0.00**

**Material**

**#N/A** 

### "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



### 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 6 

# 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: Wire Harness Connector - Vacuum Sensor Brake Booster**  

## Part Number: **060760-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**


## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **#N/A**

**T1 or OEM Total Manufacturing Cost: #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**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**

----- ----- ----- **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**Base Cost Impact to Vehicle: #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: #N/A**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**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 Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type:
Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote 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: 3 of 6 

# 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)

Wire Harness Connector - Vacuum Sensor

Brake Booster 060760-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** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  10 Cavity Mold **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **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)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **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**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 



### 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 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT



## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### 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**

**#N/A 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: 5 of 6 

# 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)

Wire Harness Connector - Vacuum Sensor

Brake Booster 060760-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** 

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 



## Purchase Part - High Impact Item (Full Cost Mapping)

**Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**

**Purchase Part - Commodity ( Value taken from Purchase Part Database)** -
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#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: 6 of 6 

# 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