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 Power Brake Subsystem ( for Hydraulics)

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)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

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

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 

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 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SUBSYSTEM ROLL-UP $ 48.11 $ 34.24 $ 44.27 $ 126.63 $ 0.74 $ 10.32 $ 9.01 $ 3.19 $ 23.26 $ 0.22 $ 150.11 $ -

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)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

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

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 

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)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

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

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 

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 Cylinder 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 INFORMATI

Item

Subsystem

Sub-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)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

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

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 

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 Cylinder 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 

Item

Subsystem

Sub-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)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

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

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 

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 Power Brake Subsystem ( for Hydraulics)

1 00

2 01

Item

Subsystem

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:

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

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

DRAFT

Item

Subsystem

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:

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

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

DRAFT

Item

Subsystem

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:

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

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 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

Item

Subsystem

Sub-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

DRAFT

Item

Subsystem

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:

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

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 Cylinder Blocks

A1 01

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-Subsystem

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ -

#REF! #REF! #REF! #REF! #REF! #REF! #REF!

Material Labor Burden End Item 

Scrap SG&A Profit 

$ - $ - $ - $ - $ - $ - $ -

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NTAL 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

DRAFT

Item

Subsystem

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:

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

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 Power Brake Subsystem ( for Hydraulics)

1 00

2 01

Item

Subsystem

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 TECHNOLOG

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

DRAFT

Item

Subsystem

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 TECHNOLOG

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

DRAFT

Item

Subsystem

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 TECHNOLOG

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 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

Item

Subsystem

Sub-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

DRAFT

Item

Subsystem

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 TECHNOLOG

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 Cylinder Blocks

A1 01

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-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

DRAFT

Item

Subsystem

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 TECHNOLOG

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 Power Brake Subsystem ( for Hydraulics)

1 00

2 01

Item

Subsystem

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

L 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

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Profit ED&T-R&D

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

L 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

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Profit ED&T-R&D

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

L COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

Item

Subsystem

Sub-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

DRAFT

Item

Subsystem

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

L 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 Cylinder Blocks

A1 01

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-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

DRAFT

Item

Subsystem

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

L 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 Power Brake Subsystem ( for Hydraulics)

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SUBSYSTEM ROLL-UP $ 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

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 TECHNOLOG

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 INFORMATION

Item

Subsystem

Sub-Subsystem

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

05 Cylinder 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)

Subsystem

Sub-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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 U

Manufacturing Total 

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Subsystem

Sub-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 Cylinder 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)

Item

Subsystem

Sub-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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 Power Brake Subsystem ( for Hydraulics)

1 00

2 01

3 02

4 03

5 04

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

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 DESCRIPTION

Item

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

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 DESCRIPTION

Item

Subsystem

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-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 Cylinder 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

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

M1 99

2

N1 00

2

SU

BS

YS

TECHNO

LOGY 

PACKAG

Subsystem

Sub-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 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

Item

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

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 Power Brake Subsystem ( for Hydraulics)

1 00

2 01

3 02

4 03

5 04

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

$ -

$ -

$ -

$ -

$ -

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 DESCRIPTION

Item

Subsystem

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 DESCRIPTION

Item

Subsystem

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

Investment(X1

000)

05 Cylinder 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

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

M1 99

2

N1 00

2

SU

BS

YS

TECHNO

LOGY 

PACKAG

Subsystem

Sub-Subsystem

Investment(X1

000)

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

Item

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

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 Power Brake Subsystem ( for Hydraulics)

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 INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

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) Wire Harness Connector - Vacuum Pressure Sensor Brake Booster (4 pin) 06 07 60 - N0502- 01 1 Full 1 Specific to HEV Application 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 $ $ -

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&D

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

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 Power Brake Subsystem ( for Hydraulics)

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 Pump 

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

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)

Item

Subsystem

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

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

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)

Item

Subsystem

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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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:

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

"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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Cost per Pallet /Rack

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InRequirements (Parts)

PACKAGING CALCULATIONS: 

3

1

Notes: 

a) Items 1,2, & 3 must a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Cost per Base: 6" Pallet Base, $100/Base Packaging Cost Total: $0.000

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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

$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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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:

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 Power Brake Subsystem ( for Hydraulics)

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-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 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 $ -

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-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 Power Brake Subsystem ( for Hydraulics)

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly.

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Net Cost Impact to Vehicle: $1.47

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

HOSE CLIP 060770-N0502-02 $0.06

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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 a

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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 a

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 Sub1 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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 

D Purchase Part - Commodity ( Value taken from Purchase Part Database) Price Net, 

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Net Cost Impact to Vehicle: $0.38

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 Sub1 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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 Sub1 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 SubAssembly.

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

3

1

Notes: 

a) Items 1,2, & 3 must 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: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

a) Items 1,2, & 3 must a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

"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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InPACKAGING CALCULATIONS: 

3

Notes: 

a) Items 1,2, & 3 must a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

$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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Net Cost Impact to Vehicle: $1.50

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

$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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

3

1

Notes: 

a) Items 1,2, & 3 must 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: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

a) Items 1,2, & 3 must a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 WASHER, 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 SubAssembly.

"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 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: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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 WASHER, 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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 WASHER, 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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 

D Purchase Part - Commodity ( Value taken from Purchase Part Database) Price Net, 

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 SubAssembly.

"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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

3

1

Notes: 

a) Items 1,2, & 3 must 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: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

a) Items 1,2, & 3 must a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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-WAVE WASHER, CONNECTER 060701-N0502-44 1 S $0.00 $0.09 $0.00 $0.09 $0.09

3 H- WASHER, 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 SubAssembly.

"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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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-WAVE WASHER, CONNECTER 060701-N0502-44

H- WASHER, 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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-WAVE WASHER, CONNECTER 060701-N0502-44

H- WASHER, 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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

4 H-SEAL, POPPET VALVE 060701-N0502-54 1 S "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to $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 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: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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)

Cost per Pallet /Rack

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InRequirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

H-SEAL, POPPET VALVE 060701-N0502-54 $0.06

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

"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 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: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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, 

Cost Unit PIA 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

Material

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

$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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

"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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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 a

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly.

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 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 shell 

retainer 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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

"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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

277 13.00 0.25

277 13.00 0.25

124 29.00 0.25

493 7.30 0.50

H-STUD PLATE, FRONT SHELL 060701-N0502-83 257 14.00 0.25

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 Asm, Populated

Level Symbol Name Number Qty Material Piece Cost

H Brake Booster Assembly H Brake ###

Booster Asm, 

Populated

1 H-REAR SHELL W/PLATES H-REAR 1

SHELL 

W/PLATES

2 H-REAR SHELL W/STUDS H-REAR 1

SHELL 

W/STUDS

3 H-REAR SHELL-Press H-REAR 1

SHELL-Press

4 H-REAR SHELL-Wash H-REAR 1

SHELL-WASH

5 H-REAR SHELL, Stamping H-REAR 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-VACUUM SEAL, REAR H-VACUUM 1 Commodity

SHELL SEAL, REAR 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 PLATE, REAR H-STUD 1

SHELL PLATE, REAR 

SHELL

3 H-STUD PLATE, REAR H-STUD 1

SHELL -Wash PLATE, REAR 

SHELL-Wash

Design Profit®

Page 1 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Level Symbol Name Number Qty Material Piece Cost

H-STUD PLATE, REAR H-STUD 

SHELL WELD PLATE, REAR 
SHELL WELD

5 H-STUD PLATE, REAR H-STUD 1

SHELL STAMPED PLATE, REAR 

SHELL 

STAMPED

6 H-STUD PLATE, REAR H-STUD 1 Steel - 1008

SHELL- Material PLATE, REAR 

SHELL 

-Material

5 H-STUD PLATE WASHER, H-STUD 4 Commodity 

REAR SHELL PLATE Pricing

WASHER, 

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 PEDAL H-CLEVIS TO 1 MIXED

PEDAL

3 H-CLEVIS TO PEDAL, H-CLEVIS TO 1 MIXED

OVERMOLDED PEDAL, 

OVERMOLDE

D

4 H-CLEVIS TO PEDAL H-CLEVIS TO 1

PLATED PEDAL 

PLATED

5 H-CLEVIS TO PEDAL, Wash H-CLEVIS TO 1

PEDAL, Wash

Design Profit®

Page 2 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Level Symbol Name Number Qty Material

H-CLEVIS TO PEDAL, H-CLEVIS TO 

WELDMENT PEDAL, 

WELDMENT

7 H-SUPPORT, CLEVIS TO H-SUPPORT, 1 Steel - 1008

PEDAL, Stamped CLEVIS TO 

PEDAL, 

Stamped

8 H-SUPPORT, CLEVIS TO H-SUPPORT, 1 Steel - 1008

PEDAL, Material CLEVIS TO 

PEDAL, 

Material
7 H-CLEVIS TO PEDAL H-CLEVIS TO 1 Steel - 1008

STAMPED PEDAL 

STAMPED

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

PEDAL CLEVIS TO 

PEDAL

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-PLATES & DIAPHRAGMS H-PLATES & 1

DIAPHRAGMS

4 H-VALVE BODY W SEAL H-VALVE 1

BODY W

SEAL

5 H-VALVE BODY- Molded H-VALVE 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 Asm, Populated

Level Symbol 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-STAR WASHER, VALVE H-STAR 1 Commodity

BODY WASHER, Pricing

VALVE BODY

6 H-STAR WASHER, VALVE H-STAR 1 Steel - 1040

BODY-Material WASHER, 

VALVE 

BODY-Material

4 H-REAR PLATE, DIAG, CUP H-REAR 1

PLATE, DIAG, 

CUP

5 H-REAR H-REAR 1 SBR

DIAPHRAGM-Molded DIAPHRAGMMolded

6 H-REAR DIAPHRAGM - H-REAR 1 SBR

Material DIAPHRAGM - 
Material

5 H-REAR PLATE, CENTER H-REAR 1 Steel - 1008

SECTION- Washed PLATE, 

CENTER 

SECTIONWashed

6 H-REAR PLATE, CENTER H-REAR 1 Steel - 1008

SECTION- Stamping PLATE, 

CENTER 

SECTIONStamping

7 H-REAR PLATE, CENTER H-REAR 1 Steel - 1008

SECTION-Material PLATE,

CENTER 

SECTION 

-Material

5 H-REAR CUP, CENTER H-REAR CUP, 1 Steel - 1008

SECTION CENTER 

SECTION

6 H-REAR CUP, CENTER H-REAR CUP, 1 Steel - 1008

SECTION-Washed CENTER 

SECTIONWashed

Design Profit®

Page 4 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Level Symbol Name Number Qty Material

7 H-REAR CUP, CENTER H-REAR CUP, Steel - 1008

SECTION- Stamping CENTER 

SECTIONStamping

8 H-REAR CUP, CENTER H-REAR CUP, 1 Steel - 1008

SECTION-Material CENTER 

SECTION 

-Material

4 H-CENTER PLATE W SEAL H-CENTER 1

PLATE W 

SEAL

5 H-CENTER PLATE H-CENTER 1 Steel - 1008

PLATE

6 H-CENTER PLATE- Stamping H-CENTER 1 Steel - 1008

PLATEStamping

7 H-CENTER PLATE-Material H-CENTER 1 Steel - 1008

PLATE 

-Material

5 H-SEAL, CENTER PLATE- H-SEAL, 1 EDPM

Molded CENTER 

PLATEMolded

6 H-SEAL, CENTER PLATE- H-SEAL, 1 EPDM

Material CENTER 

PLATE 

-Material

4 H-FRONT PLATE H-FRONT 1 Steel - 1018
PLATE

5 H-FRONT PLATE, Stamped H-FRONT 1 Steel - 1018

PLATE, 

Stamped

6 H-FRONT PLATE BLANK H-FRONT 1 Steel - 1018

PLATE BLANK

4 H-CENTER DIAPHRAGM- H-CENTER 1 SBR

Molded DIAPHRAGMMolded

5 H-CENTER DIAPHRAGM - H-CENTER 1 SBR

Material DIAPHRAGM 

-Material

Design Profit®

Page 5 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Level Symbol Name Number Qty Material Piece Cost

H-C0NNECTOR, INPUT ROD HTO SOLENOID C0NNECTOR, 

INPUT ROD 

TO 

SOLENOID

4 H-HOUSING, CONNECTOR- H-HOUSING, 1 PPS GF40

Molded CONNECTORMolded

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-WAVE WASHER, H-WAVE 1 Commodity 

CONNECTOR WASHER, Pricing

CONNECTOR

4 H-WASHER, CONNECTOR H-WASHER, 1 Commodity 

CONNECTOR Pricing

4 H-RETAINER, CONNECTOR- H-RETAINER, 1 PPS GF40

Molded CONNECTORMolded

5 H-RETAINER, CONNECTOR H-RETAINER, 1 PPS GF40

-Material CONNECTOR 

-Material

3 H-INPUT ROD ASSEMBLY H-INPUT ROD 1

ASSEMBLY

4 H-INPUT ROD, VALVE BODY H-INPUT ROD, 1 Steel - 1018

VALVE BODY

5 H-INPUT ROD, VALVE H-INPUT ROD, 1 Steel - 1018

BODY-Machined VALVE 

BODYMachined

6 H-INPUT ROD, VALVE H-INPUT ROD, 1 Steel - 1018

BODY-Material VALVE 

BODY-Material

4 H-RETAINER, INPUT ROD H-RETAINER, 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 Asm, Populated

Level Symbol Name Number Qty Material Piece Cost

H-SPRING, INPUT ROD H-SPRING, 1 Commodity 

INPUT ROD Pricing

4 H-RETAINER, POPPET H-RETAINER, 1 PET-GF 36

SPRING WITH SEAL POPPET 

SPRING WITH 

SEAL

5 H-RETAINER, POPPET H-RETAINER, 1 PET-GF 36

SPRING WITH SEAL-Material POPPET 

SPRIN WITH 

SEAL-Material

4 H-SPRING, POPPET VALVE H-SPRING, 1 Commodity 

POPPET Pricing

VALVE

4 H-POPPET, VALVE BODY H-POPPET, 1

VALVE BODY

5 H-WASHER, POPPET, VALVE H-WASHER, 1 Commodity 

BODY-Material POPPET, Prcing

VALVE BODY

5 H-POPPET, VALVE H-POPPET, 1 SBR

BODY-Material VALVE 

BODY-Material

4 H-PLUNGER VALVE BODY H-PLUNGER 1 Steel - 1018

VALVE BODY

5 H-PLUNGER VALVE BODY H-PLUNGER 1 Steel - 1018

VALVE 

BODYMachined

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 Asm, Populated

Level Symbol 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-REACTION DISK H-REACTION 1

ASSEMBLY DISK 

ASSEMBLY

3 H Retainer, Reaction Disc H Retainer, 1 A380

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 Assembly H Output Rod 1

Assembly

Design Profit®

Page 8 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Level Symbol 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 Washer, Output Rod, 0.59 H Washer, 1 Commodity 

mm Output Rod, Pricing

0.59 mm

3 H Washer, Output Rod, 0.10 H Washer, 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 Asm, Brake H Front Shell 1

Booster Asm, Brake 

Booster

2 H Front Shell Asm, Painted H Front Shell 1

Asm, Painted

3 H Front Shell Asm, Washed H Front Shell 1

Asm, Washed

4 H Front Shell Asm, Pressed H Front Shell 1 Steel - 1008

Together Asm, Pressed 

Together

Design Profit®

Page 9 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Level Symbol 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 PA66 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 Asm, Populated

Level Symbol Name Number Qty Material Piece Cost

H Retainer, Front Shell H Retainer, PA66 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 MASTER CYLINDER H MASTER 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 Asm, Populated

Level Symbol Name Number Qty Material Piece Cost

Assembly Totals Report Totals

Analyzed Subs:84 Piece Cost (Total): $11.36

Unanalyzed Subs: 4

Weight (Total): 11.7095 lb

Parts: 82

Fasteners: 16

Parts+Unanalyzed: 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 Asm, Populated

Labor Type Parent Name Symbol 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-Wash H-REAR 3.0000 sec

SHELL-Press SHELL-WASH

$20.81 Tool H-REAR Washer Turbo Tunnel 0.0000 sec

SHELL-Wash

- - - In-Line Washer - -

$106.69 $106.69 P.-P. Part P.-P. Part H-REAR H-REAR SHELL, Stamping H-REAR SHELL, Stamping H-REAR SHELL, H-REAR SHELL, 3.0000 sec 3.0000 sec

SHELL-Wash 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 Asm, Populated

Labor Type Parent Name Symbol Name Number Munro 

Rate Score

$20.81 Operation H-REAR Load Part 3.0000 sec

SHELL-Wash

$20.81 Operation H-REAR Wash Part Medium 5.0000 sec

SHELL-Wash
$20.81 Operation H-REAR Unload Part 2.0000 sec

SHELL-Wash

$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 Asm, Populated

Labor Type Parent Name Symbol 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 -Wash REAR 

SHELL-Wash

$20.81 Tool H-STUD PLATE, Washer Turbo Tunnel 0.0000 sec

REAR SHELL 

-Wash

- - - In-Line Washer - -

$24.36 P.-P. Part H-STUD PLATE, H-STUD PLATE, REAR SHELL H-STUD PLATE, 3.0000 sec

REAR SHELL WELD REAR SHELL 

-Wash WELD

$24.36 Tool H-STUD PLATE, Spot Welder 0.0000 sec

REAR SHELL 
WELD

- - - Spot-Projection Weld 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 

WELD 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 WASHER, H-STUD PLATE 3.0000 sec

REAR SHELL REAR SHELL WASHER, REAR 

WELD SHELL

$24.36 Fastening H-STUD PLATE, Projection Weld 3.0000 sec

REAR SHELL 

WELD

$20.81 Operation H-STUD PLATE, Load Part 3.0000 sec

REAR SHELL 

-Wash

$20.81 Operation H-STUD PLATE, Wash Part Medium 5.0000 sec

REAR SHELL 

-Wash

Design Profit ®

Page 3 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Labor Type Parent Name Symbol Name Number Munro 

Rate Score

$20.81 Operation H-STUD PLATE, Unload Part 2.0000 sec

REAR SHELL 

-Wash

$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 Asm, Populated

Labor Type Parent Name Symbol 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, Wash H-CLEVIS TO 3.0000 sec

PEDAL PLATED PEDAL, Wash

$10.75 Tool H-CLEVIS TO Washer Duo 400 Wash Rinse & 0.0000 sec

PEDAL, Wash DRY

$44.96 Subassembly H-CLEVIS TO H-CLEVIS TO PEDAL, H-CLEVIS TO 3.0000 sec
PEDAL, Wash WELDMENT PEDAL, 

WELDMENT

$44.96 Tool H-CLEVIS TO Laser Welder 0.0000 sec

PEDAL, 

WELDMENT

$15.50 P.-P. Part H-CLEVIS TO H-SUPPORT, CLEVIS TO H-SUPPORT, 3.0000 sec

PEDAL, PEDAL, Stamped CLEVIS TO 

WELDMENT 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 Asm, Populated

Labor Type Parent Name Symbol 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 

WELDMENT 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, 

WELDMENT

$44.96 Operation H-CLEVIS TO Clamp Part 3.0000 sec

PEDAL, 

WELDMENT

$44.96 Fastening H-CLEVIS TO Laser Weld 1.0000 sec

PEDAL, 

WELDMENT

$10.75 Operation H-CLEVIS TO Load Part 3.0000 sec

PEDAL, Wash

$10.75 Operation H-CLEVIS TO Wash Part Medium 5.0000 sec

PEDAL, Wash

$10.75 Operation H-CLEVIS TO Unload Part 2.0000 sec

PEDAL, Wash

$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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated
Labor Type Parent Name Symbol 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 sec10.0000 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.

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Labor Type Parent Name Symbol Name Number Munro 

Rate Score

$0.00 P.-P. Part H-VALVE BODY H-STAR WASHER, VALVE H-STAR 5.0000 sec

W SEAL BODY WASHER, 

VALVE BODY

$0.00 Tool H-STAR Stamping Press 0-60 Ton 0.0000 sec

WASHER, 

VALVE BODY
$0.00 Part H-STAR H-STAR WASHER, VALVE H-STAR 0.0000 sec

WASHER, BODY-Material WASHER, 

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 Asm, Populated

Labor Type Parent Name Symbol 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- Washed CENTER 

SECTIONWashed

$20.81 Tool H-REAR PLATE, Washer Turbo Tunnel 0.0000 sec

CENTER 

SECTIONWashed
- - - In-Line Washer - -

$42.91 P.-P. Part H-REAR PLATE, H-REAR PLATE, CENTER H-REAR PLATE, 5.0000 sec

CENTER SECTION- Stamping CENTER 

SECTION- SECTIONWashed 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 

SECTIONWashed

$20.81 Operation H-REAR PLATE, Wash Part Medium 5.0000 sec

CENTER 

SECTIONWashed

Design Profit ®

Page 10 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Labor Type Parent Name Symbol Name Number Munro 

Rate Score

$20.81 Operation H-REAR PLATE, Unload Part 2.0000 sec

CENTER 

SECTIONWashed

- - - 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-Washed CENTER 

SECTION SECTIONWashed

$20.81 Tool H-REAR CUP, Washer Turbo Tunnel 0.0000 sec

CENTER 

SECTION-
Washed

- - - In-Line Washer - -

$24.60 P.-P. Part H-REAR CUP, H-REAR CUP, CENTER H-REAR CUP, 3.0000 sec

CENTER SECTION- Stamping CENTER 

SECTION- SECTIONWashed 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.

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Labor Type Parent Name Symbol 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 

SECTIONWashed

$20.81 Operation H-REAR CUP, Wash Part Medium 5.0000 sec

CENTER 

SECTIONWashed

$20.81 Operation H-REAR CUP, Unload Part 2.0000 sec

CENTER 

SECTIONWashed

$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 sec13.6170 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 Asm, Populated

Labor Type Parent Name Symbol 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 Washer Turbo Tunnel 0.0000 sec

PLATE

- - - In-Line Washer - -

$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 Wash 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.

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Labor Type Parent Name Symbol 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 Washer 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 Asm, Populated

Labor Type Parent Name Symbol Name Number Munro 

Rate Score

- - - Part Size after stamping (220 L - -

by 220W by 20 H)mm

- - - In-Line Washer - -
$20.81 Operation H-FRONT PLATE Load Part 3.0000 sec

$20.81 Operation H-FRONT PLATE Wash 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.

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Labor Type Parent Name Symbol 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-WAVE WASHER, H-WAVE 5.0000 sec

INPUT ROD TO CONNECTOR WASHER, 

SOLENOID CONNECTOR

- - - STAINLESS STEEL WASHER - -

$35.51 Part H-C0NNECTOR, H-WASHER, CONNECTOR H-WASHER, 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.

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Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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

- - - "Washing, Small Size and/or Low - -

Complexity"

$10.75 Tool H-INPUT ROD, Washer Duo 400 Wash 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.

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Labor Type Parent Name Symbol 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 Washer - -

- - - 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, Wash Part Medium 5.0000 sec

VALVE BODY
Design Profit ®

Page 19 of #

Copyright 2005© Munro & Associates, Inc.

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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 WITH SEAL POPPET 

SPRING WITH 

SEAL

$16.39 Tool H-RETAINER, Injection Molding Machine 55-150 0.0000 sec

POPPET ton

SPRING WITH 

SEAL

$16.39 Part H-RETAINER, H-RETAINER, POPPET SPRING H-RETAINER, 0.0000 sec

POPPET WITH SEAL-Material POPPET SPRIN 

SPRING WITH WITH 

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 Asm, Populated

Labor Type Parent Name Symbol 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 WASHER ARE SAME - -

$16.39 Part H-POPPET, H-WASHER, POPPET, VALVE H-WASHER, 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 Asm, Populated

Labor Type Parent Name Symbol 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 Washer Duo 400 Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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 Washer - -

- - - 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 Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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, Washer Duo 400 Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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, Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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, Washer Duo 400 Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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, Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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 Washer Duo 400 Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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 Wash 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 Asm, Populated

Labor Type Parent Name Symbol Name Number Munro 

Rate Score

- - - Space for printing - -

- - - Space for printing - -

$35.51 Part H Output Rod H Washer, Output Rod, 0.59 mm H Washer, 6.0000 sec

Assembly Output Rod, 0.59 

mm

$35.51 Part H Output Rod H Washer, Output Rod, 0.10 mm H Washer, 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 Washer Duo 400 Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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 Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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, Washer Duo 400 Wash 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, Wash 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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, Washed H Front Shell 3.0000 sec

Asm, Painted Asm, Washed

$20.81 Tool H Front Shell Washer Turbo Tunnel 0.0000 sec

Asm, Washed

- - - In-Line Washer - -

$42.18 P.-P. Part H Front Shell H Front Shell Asm, Pressed H Front Shell 3.0000 sec

Asm, Washed 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 $141.76 Part H Front Shell H Front Shell H Front Shell, Material H Front Shell, Material H Front Shell, H Front Shell, 0.0000 sec 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 Asm, Populated

Labor Type Parent Name Symbol 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, Washed

$20.81 Operation H Front Shell Wash Part Medium 5.0000 sec

Asm, Washed

Design Profit ®

Page 40 of #

Copyright 2005© Munro & Associates, Inc.

H Brake Booster Asm, Populated

Labor Type Parent Name Symbol Name Number Munro 

Rate Score

$20.81 Operation H Front Shell Unload Part 2.0000 sec

Asm, Washed

$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 Weld - -

$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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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 Asm, Populated
Labor Type Parent Name Symbol 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 Asm, Populated

Labor Type Parent Name Symbol 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 sec11.0000 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 Asm, Populated

Labor Type Parent Name Symbol 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 -

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0.0000 sec $0.00 $0.00 1 $0.00

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5.0000 sec $0.00 $0.03 1 $0.00

2.0000 sec $0.00 $0.01 1 $0.00
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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

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6.0000 sec $0.00 $0.06 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

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0.0000 sec $0.00 $0.00 1 $0.00

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1.7000 sec $0.66 $0.01 1 $0.66

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6.0000 sec $0.00 $0.06 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

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2.1800 sec $0.25 $0.05 1 $0.25

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Cost (Total) (Total)

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2.5220 sec $0.10 $0.01 1 $0.10

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2.0000 sec $0.00 $0.02 1 $0.00

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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

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5.0000 sec $0.00 $0.01 1 $0.00
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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

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0.9870 sec $0.01 $0.00 1 $0.01

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5.0000 sec $0.00 $0.03 1 $0.00

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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

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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

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2.0000 sec $0.00 $0.01 1 $0.00

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6.0000 sec $0.00 $0.06 1 $0.00

5.0000 sec $0.00 $0.05 1 $0.00

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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

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0.7000 sec $0.08 $0.00 1 $0.08

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Cost (Total) (Total)

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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

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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

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Cost (Total) (Total)

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5.0000 sec $0.00 $0.06 1 $0.00

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2.0000 sec $0.00 $0.02 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

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Cost (Total) (Total)

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Cost (Total) (Total)

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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 Assembly, Populated Part # QTY

x H-BRAKE BOOSTER ASSEMBLY, POPULATED 1

x H-MASTER CYLINDER ASM 1

x H-NUT, CYLINDER TO BOOSTER 2

x H-VACUUM HOSE, BOOSTER 1

x A H-BRAKE BOOSTER ASSEMBLY 1

x H-SPRING, LARGE BRAKE BOOSTER 1

x H-LABEL, BRAKE BOOSTER, FRONT SHELL 1

x B H-REAR SHELL W/PLATES 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-REAR SHELL W/STUDS 1

x H- REAR SHELL, STAMPED 1

x H-STUD, REAR SHELL 4

x B2 H-STUD PLATE, REAR SHELL 1

x H-STUD PLATE, STAMPED 1

x H-STUD PLATE WASHER, REAR SHELL 4

x B3 H-CLEVIS TO PEDAL 1

x H-BUMPER, CLEVIS TO PEDAL 2

x B3A H-SUPPORT,CLEVIS TO PEDAL PLATED 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-PLATES & DIAPHRAGMS 1

x H-FRONT PLATE 1

x H-CENTER DIAPHRAGM,MOLDED 1

x B4A1 H-VALVE BODY W SEAL 1

x H-VALVE BODY,MOLDED 1

x H - VALVE BODY SQ CUT, MOLDED 1

x H- STAR WASHER, VALVE BODY 1

x B4A2 H-REAR PLATE, DIAG. 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 PLATE W SEAL 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-WAVE WASHER, CONNECTER

1

x H- WASHER, CONNECTER1

x H-RETAINER CONNECTER1

x B4C H-INPUT ROD ASSEMBLY1

x H-INPUT ROD VALVE, BODY1

x H-RETAINER INPUT ROD SPRING1

x H-SPRING, INPUT ROD1

x H-RETAINER POPPET SPRING1

x H- SPRING, POPPET VALVE1

x H-POPPET VALVE BODY1

x H-WASHER, POPPET VALVE BODY1

x H-PLUNGER, VALVE BODY1

x H-SEAL, POPPET VALVE1

x B4D H- KEY, BOOSTER1

x H-KEY BOOSTER, MATE1

x H- KEY, BOOSTER, METAL1

x B5 H- REACTION DISK ASSEMBLY1

x H-RETAINER, REACTION DISK1

x H-PISTON, REACTION DISK1

x H-REACTION DISK1

x B6 H-OUTPUT ROD ASSEMBLY1

x H-ROD OUTPUT1

x H-WASHER, OUTPUT ROD .591

x H-WASHER, OUTPUT ROD .101

x H-SOCKET, OUTPUT ROD1

x H-RETAINER, OUTPUT ROD1

x B7 H-SOLENOID W SEAL, BOOSTER1

x H-SOLENOID, BOOSTER1

x H- LIP SEAL, SOLENOID BOOSTER1

xC H-FRONT SHELL ASSEMBLY, BRAKE BOOSTER1

x H-VACUUM HOSE SEAL,FRONT SHELL1

x H-VACUUM HOSE FITTING, FRONT SHELL1

x H-RETAINER,FRONT SHELL1

x H-O RING, RETAINER,FRONT SHELL1

x H-POSITION SENSOR, FRONT SHELL1

x H-O RING SENSOR,FRONT SHELL1

x H-C CLIP, FRONT SHELL1

x H-RETAINER, FRONT SHELL1

x H-O RING, RETAINER,FRONT SHELL1

x H-PRESSURE SENSOR, FRONT SHELL1

x H-O RING SENSOR,FRONT SHELL1

x H-C CLIP, FRONT SHELL1

x H-ELECTRICAL HARNESS, FRONT SHELL1

x H-O RING, RETAINER,FRONT SHELL1

x H-O RING, RETAINER,SMALL,FRONT SHELL1

x H-HARNESS RETAINER, FRONT SHELL1

x C1 H-FRONT SHELL ASSEMBLY, PAINTED1

x H- FRONT SHELL, STAMPED1

x H-STUD PLATE, FRONT SHELL1

x H- STUD SHORT,FRONT SHELL2
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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 Sub1 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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411