Page:1 of 1 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)

Item

System

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