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# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFT

Material Labor Burden End Item

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

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

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD**



# 01 **Engine**

**01 System downsize (2.7L I4 to 2.4L I4)**  **441.58**

**- -**  **441.58**

**- -**  **- -**  **- -**  **441.58**

**- -**  **480.00**

**- -**  **480.00**

**- -**  **- -**  **- -**  **480.00**

**- -**  **- 38.42** 

**- -**  **38.42**

**- -**  **- -**  **- -**  **38.42**

**- -**  **-**



### 1 **02 Engine Frames, Mounting, and Brackets Subsystem**  **2.57 0.70**  **2.20 5.47**  **0.19 0.57**  **0.44 0.09**  **1.29 0**  **6.76**

**- 3,837.20** 

**- 2.76**  **0.86 1.91**  **5.52 0.12**  **0.58 0.39**  **0.05 1.15**  **0 6.67** 

**- 1,058.60** 

**- 0.19**  **0.16 (0.30)**  **0.05 (0.07)**  **0.01 (0.05)**  **(0.03) (0.14)**  **0 (0.09)** 

**- (2,778.60)** 

**-**



### 2 **03 Crank Drive Subsystem**  **5.35 3.90**  **16.28 25.53**  **0.17 2.24**  **2.06 0.69**  **5.16 0**  **30.69**

**- 320.00** 

**- 7.00**  **5.38 18.70**  **31.07 0.21**  **2.88 2.58**  **0.82 6.49**  **0 37.57** 

**- 622.80** 

**- 1.64**  **1.48 2.42**  **5.54 0.04**  **0.64 0.52**  **0.13 1.34**  **0 6.88** 

**- 302.80** 

**-**



### 3 **04 Counter Balance Subsystem (NA)** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 4 **05 Cylinder Block Subsystem**  **88.72 9.40**  **45.08 143.20**  **4.10 8.01**  **5.73 1.31**  **19.15 0**  **162.34**

**- 20,742.00** 

**- 76.16**  **6.96 32.58**  **115.70 1.48**  **6.87 4.90**  **1.07 14.32**  **0 130.02** 

**- 17,824.00** 

**- (12.55)**  **(2.44) (12.50)**  **(27.50) (2.62)**  **(1.13) (0.83)**  **(0.24) (4.83)**  **0 (32.33)** 

**- (2,918.00)** 

**-**



### 5 **06 Cylinder Head Subsystem**  **4.64 0.95**  **1.50 7.09**  **0.03 0.50**  **0.43 0.11**  **1.07 0**  **8.16**

**- 301.00** 

**- 9.57**  **1.65 4.92**  **16.15 0.58**  **1.60 1.36**  **0.35 3.89**  **0 20.04** 

**- 2,500.60** 

**- 4.93**  **0.71 3.42**  **9.06 0.54**  **1.11 0.94**  **0.24 2.83**  **0 11.89** 

**- 2,199.60** 

**-**



### 6 **07 Valvetrain Subsystem**  **15.50 12.72**  **33.25 61.47**  **0.54 4.49**  **4.94 2.25**  **12.23 0**  **73.70**

**- 3,405.20** 

**- 18.53**  **7.44 24.00**  **49.97 1.13**  **4.59 4.90**  **1.98 12.60**  **0 62.57** 

**- 1,234.20** 

**- 3.03**  **(5.28) (9.25)**  **(11.50) 0.58**  **0.09 (0.04)**  **(0.27) 0.37**  **0 (11.13)** 

**- (2,171.00)** 

**-**



### 7 **08 Timing Drive Subsystem**  **12.43 0.87**  **0.99 14.29**  **0.12 1.49**  **1.26 0.30**  **3.16 0**  **17.45**

**- 1,619.20** 

**- 7.39**  **2.55 7.08**  **17.02 0.83**  **2.09 1.69**  **0.60 5.22**  **0 22.24** 

**- 5,141.60** 

**- (5.04)**  **1.68 6.09**  **2.73 0.72**  **0.61 0.43**  **0.30 2.06**  **0 4.79** 

**- 3,522.40** 

**-**



### 8 **09 Accessory Drive Subsystem (NA)** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 9 **10 Air Intake Subsystem**  **8.59 0.75**  **0.84 10.18**  **0.06 0.97**  **0.78 0.15**  **1.96 0**  **12.14**

**- 241.70** 

**- 9.04**  **1.60 2.06**  **12.70 0.16**  **1.16 0.95**  **0.18 2.45**  **0 15.15** 

**- 2,166.40** 

**- 0.45**  **0.85 1.22**  **2.52 0.10**  **0.19 0.17**  **0.03 0.49**  **0 3.01** 

**- 1,924.70** 

**-**



### 10 **11 Fuel Induction Subsystem**  **0.66 0.05**  **0.04 0.74**  **0.00 0.08**  **0.05 0.01**  **0.14 0**  **0.89**

**- 270.50** 

**- 0.88**  **0.49 1.01**  **2.39 0.10**  **0.27 0.21**  **0.04 0.62**  **0 3.01** 

**- 1,803.90** 

**- 0.22**  **0.44 0.98**  **1.64 0.10**  **0.19 0.16**  **0.04 0.48**  **0 2.13** 

**- 1,533.40** 

**-**



### 11 **12 Exhaust Subsystem** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **Total**

**Packaging**

**Cost**

**(Component/**

**Assembly) Net** 

**Component/**

**Assembly Cost**

**Impact to OEM** Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Investment** 

**(X1000)** Markup 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**

**Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component/**

**Assembly) Net** 

**Component/**

**Assembly Cost**

**Impact to OEM Investment** 

**(X1000) Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000)** 

# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**ItemSystem 

# NEW TECHNOLOGY GENERAL PART INFORMATION:Subsystem



### Sub-Subsystem Description **System**

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(X1000)** Manufacturing

**Net**

**Component/**

**Assembly Cost**

**Impact to OEM Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component/**

**Assembly)** 

# Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

**Vehicle Class:** Sub

- Compact Size Passenger Vehicle, 3

- 4 Passengers



# Study Case#: N0200 (N=New, 02=Multi

- Air, 00 =Subcompact Vehicle Class)

11 **12 Exhaust Subsystem** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 12 **13 Lubrication Subsystem**  **1.01 0.19**  **0.14 1.33**  **0.01 0.15**  **0.14 0.04**  **0.35 0**  **1.69**

**- 284.50** 

**- 0.74**  **0.24 0.22**  **1.21 0.01**  **0.13 0.11**  **0.03 0.28**  **0 1.48** 

**- 311.00** 

**- (0.26)**  **0.06 0.08**  **(0.13) (0.00)**  **(0.02) (0.03)**  **(0.02) (0.07)**  **0 (0.20)** 

**- 26.50** 

**-**



### 13 **14 Cooling Subsystem**  **35.12 12.06**  **22.46 69.64**  **0.52 4.76**  **4.02 1.31**  **10.62 0**  **80.25**

**- 3,663.30** 

**- 36.97**  **12.90 23.38**  **73.25 0.70**  **5.14 4.37**  **1.41 11.62**  **0 84.87** 

**- 6,640.90** 

**- 1.85**  **0.84 0.92**  **3.62 0.18**  **0.38 0.35**  **0.09 1.00**  **0 4.62** 

**- 2,977.60** 

**-**



### 14 **15 Induction Air Charging Subsystem (NA)** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 15 **16 Exhaust Gas Re-circulation Subsystem (NA)** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 16 **17 Breather Subsystem**  **0.95 0.17**  **0.14 1.27**  **0.01 0.14**  **0.15 0.06**  **0.36 0**  **1.62**

**- 359.80** 

**- 1.56**  **0.87 2.51**  **4.94 0.18**  **0.59 0.62**  **0.23 1.62**  **0 6.56** 

**- 2,079.90** 

**- 0.61**  **0.69 2.37**  **3.67 0.17**  **0.45 0.47**  **0.17 1.26**  **0 4.93** 

**- 1,720.10** 

**-**



### 17 **60 Engine Management, Engine Electronic, Electrical Subsystem**  **1.15 0.21**  **0.16 1.51**  **0.01 0.16**  **0.15 0.05**  **0.39 0**  **1.90**

**- 74.00** 

**- 1.26**  **0.74 0.29**  **2.29 0.02**  **0.26 0.24**  **0.08 0.61**  **0 2.90** 

**- 415.00** 

**- 0.11**  **0.53 0.13**  **0.78 0.01**  **0.10 0.09**  **0.03 0.22**  **0 1.00** 

**- 341.00** 

**-**



### 18 **70 Accessory Subsystems (Start Motor, Generator, etc.)**  **1.25 0.38**  **1.18 2.81**  **0.10 0.29**  **0.31 0.12**  **0.82 0**  **3.63**

**- 1,418.90** 

**- 1.66**  **0.07 0.89**  **2.62 0.10**  **0.30 0.28**  **0.10 0.78**  **0 3.40** 

**- 630.60** 

**- 0.41**  **(0.31) (0.30)**  **(0.19) (0.00)**  **0.01 (0.02)**  **(0.02) (0.04)**  **0 (0.23)** 

**- (788.30)** 

**-**



### 619.51 **42.35 124.26**  **786.12 5.88**  **23.84 20.47**  **6.49 56.68**  **0 842.80** 

**- 36,537.30** 

**-** 

### 653.53 **41.76 119.55**  **814.84 5.61**  **26.47 22.62**  **6.94 61.65**  **0 876.49** 

**- 42,429.50** 

**-** 

### 34.02 **(0.59) (4.71)**  **28.72 (0.27)**  **2.63 2.15**  **0.46 4.97**  **0 33.69** 

**- 5,892.20** 

**-**

Tooling Saving $5,892 Ann Volume 450,000

Ann Volume 450,000 Tooling $/pc $2.62

Tooling $/pc $2.62 

### SUBSYSTEM ROLL-UP

09000064810d3b0c.xls

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

(248)373-6000 Ext. 2411