Page:1 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

021300 OE Transmission Assembly Line - Final

1 00 Assembly of High Voltage Traction Battery Subsystem $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

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

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

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

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

SUBSYSTEM ROLL-UP $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

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

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

Item

Subsystem

Sub-Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

BASE 

TECHNO

LOGY 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Total Markup 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

BASE TECHNOLOG

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

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

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

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! $ - $ - $ - #REF! #REF! #REF! #REF!

Material Labor Burden End Item 

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

05 Cylinder Blocks

A1 01 $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ - $ - $ - $ - $ - $ - $ -

B1 02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

F1 66 $ - $ - $ - $ -

Item

Subsystem

Sub-Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE INCREMENTAL COST TO U

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

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

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

I1 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

M1 99 $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ - $ $ - $ $ - $ $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

021300 OE Transmission Assembly Line - Final

1 00

0 n/a

0 n/a

0 n/a

0 n/a

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ - $ -

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

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

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

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

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

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

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

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

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

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

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

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

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

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

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

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

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

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

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

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

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

0 n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

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

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ - $ -

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

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

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

Item

Subsystem

Sub-Subsystem

BASE 

TECHNO

LOGY 

End Item 

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

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

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

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

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

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

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

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

Investment

(X1000)

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY PACKAGE COST INFORMATION

Tooling 

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

G1 67

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

H1 70

2

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

2

N1 00

End Item 

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

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

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

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

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

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

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

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

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

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

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

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

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

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

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

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

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2

SU

BS

YS

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

Item

Subsystem

Sub-Subsystem

TECHNO

LOGY 

PACKAG

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

End Item 

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

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

$ - $ -

Tooling 

(x1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Investment

(X1000)

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

End Item 

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

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

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

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

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

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

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

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

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

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

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

M1 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00

SU

BS

YS

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

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

#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: 8/23/2012

DRAFT

021300 OE Transmission Assembly Line - Final

1 00

0 n/a

0 n/a

0 n/a

0 n/a

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

0 n/a

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

0 n/a $ -

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Investment(X1

000)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

Item

Subsystem

Sub-Subsystem

BASE 

TECHNO

LOGY 

G1 67

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

H1 70

2

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

2

N1 00

Investment(X1

000)

2

SU

BS

YS

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

Item

Subsystem

Sub-Subsystem

TECHNO

LOGY 

PACKAG

F1 66

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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

Investment(X1

000)

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 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

021300 OE Transmission Assembly Line - Final

1 00 Assembly of High Voltage Traction Battery Subsystem $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ -

A A OE Transmission Assembly Line - Final 02 # 00 - N0502- 01 1 Full 1 $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ -

2 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

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

Subassembly

Component

Sub-Subsystem

Assembly

Name/Description Part Number

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

2 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

4 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

9 tbd $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

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

B H Bolt Battery Terminal Bottom 14 03 80 - N0502- 02 52 Full 1 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

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

Subassembly

Component

Sub-Subsystem

Assembly

Name/Description Part Number

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

10 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

11 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

12 tbd $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

$ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ -

NOTES:

1.

YES 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:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0 n/a n/a

021300 OE Transmission Assembly Line - Final

1 00 Assembly of High Voltage Traction Battery Subsystem

A A OE Transmission Assembly Line - Final 02 # 00 - N0502- 01 1 Full 1

2 tbd

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

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

Subassembly

Component

Sub-Subsystem

Assembly

Name/Description Part Number

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

2 tbd

3 tbd

4 tbd

5 tbd

6 tbd

7 tbd

8 tbd

9 tbd

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

9 tbd $ - $ -

B H Bolt Battery Terminal Bottom 14 03 80 - N0502- 02 52 Full 1

$ - $ -

$ - $ -

$ - $ -

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: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

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

Subassembly

Component

Sub-Subsystem

Assembly

Name/Description Part Number

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

10 tbd

11 tbd

12 tbd

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

NOTES:

1.

YES 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 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

021300 OE Transmission Assembly Line - Final

1 00 Assembly of High Voltage Traction Battery Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

System 

ED&T/R&D

(x1000)

Markup

Sub-Subsystem

Part Number

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

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

4 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

9 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

10 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

11 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

12 tbd 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

System 

ED&T/R&D

(x1000)

Markup

Sub-Subsystem

Part Number

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

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

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)

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: 8/23/2012

DRAFT

0

021300 OE Transmission Assembly Line - Final

1 00 Assembly of High Voltage Traction Battery Subsystem

2 tbd 0

3 tbd 0

QTY/ Subsystem

Notes

Sub-Subsystem

Part Number

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE 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#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

4 tbd 0

5 tbd 0

6 tbd 0

7 tbd 0

8 tbd 0

9 tbd 0

10 tbd 0

11 tbd 0

12 tbd 0

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

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: 8/23/2012

DRAFT

QTY/ Subsystem

Notes

Sub-Subsystem

Part Number

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE 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#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

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)

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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 VO Transmission Assembly Oper 5 140300-N0502-01-01 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

2 2A VO Transmission Assembly Oper 10 140300-N0502-01-02 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

3 3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03 1 Washer OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

4 4A VO Transmission Assembly Oper 15 140300-N0502-01-04 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

5 5A VO Transmission Assembly Oper 20 140300-N0502-01-05 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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 6A VO Transmission Assembly Oper 30 140300-N0502-01-06 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

7 7A VO Transmission Assembly Oper 40 140300-N0502-01-07 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

8 8A VO Transmission Assembly Oper 50 140300-N0502-01-08 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

9 9A VO Transmission Assembly Oper 60 140300-N0502-01-09 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

10 10A VO Transmission Assembly Oper 70 140300-N0502-01-10 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

11 11A VO Transmission Assembly Oper 80 140300-N0502-01-11 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

12 12A VO Transmission Assembly Oper 90 140300-N0502-01-12 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

13 13A VO Transmission Assembly Oper 100 140300-N0502-01-13 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

14 14A VO Transmission Assembly Oper 110 140300-N0502-01-14 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

15 15A VO Transmission Assembly Oper 120 140300-N0502-01-15 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

16 16A VO Transmission Assembly Oper 130 140300-N0502-01-16 1 Functional Test OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

17 17A VO Transmission Assembly Oper 140 140300-N0502-01-17 1 Functional Test OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

18 18A VO Transmission Assembly Oper 150 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

19 18A VO Transmission Assembly Oper 160 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

20 20A VO Transmission Assembly Oper 170 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

OEM, LMC

21 21A VO Transmission Assembly Oper 180 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

22 22A VO Transmission Assembly Oper 190 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

23 23A VO Transmission Assembly Oper 200 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

24 24A VO Transmission Assembly Oper 210 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

25 25A VO Transmission Assembly Oper 220 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $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 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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)

26 26A VO Transmission Assembly Oper 230 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

27 27A VO Transmission Assembly Oper 240 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

28 28A VO Transmission Assembly Oper 250 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

29 29A VO Transmission Assembly Oper 260 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

30 30A VO Transmission Assembly Oper 270 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

31 31A VO Transmission Assembly Oper 280 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

Assembly, OEM, MC

32 32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 1 Gage OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

33 33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18 1 RTV OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

34 34A VO Transmission Assembly Oper 290 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

35 35A VO Transmission Assembly Oper 300 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 2 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $1.30 $0.17 $1.47 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.47 $1.47 $0.00

36 36A VO Transmission Assembly Oper 310 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

37 37A VO Transmission Assembly Oper 320 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

38 38A VO Transmission Assembly Oper 330 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

39 39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 1 Gage OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

150 0 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $0.00 $0.83 $0.83 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.83 $0.83 $0.00

40 40 VO Transmission Assembly Oper 340 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

41 41A VO Transmission Assembly Oper 350 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

42 42A VO Transmission Assembly Oper 360 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

43 43A VO Transmission Assembly Oper 370 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

44 44A VO Transmission Assembly Oper 380 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

45 45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 1 Press OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

46 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 46 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00 Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

47 47A VO Transmission Assembly Oper 400 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

48 48A VO Transmission Assembly Oper 410 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

49 49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 1 Press OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

50 50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 1 Press OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

51 51A VO Transmission Assembly Oper 420 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $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: 3 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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)

52 52A VO Transmission Assembly Oper 430 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

53 53A VO Transmission Assembly Oper 440 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

54 54A VO Transmission Assembly Oper 450 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

55 55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 1 Gage OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

150 1 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $0.65 $0.83 $1.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.48 $1.48 $0.00

56 56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

57 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC 57 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

58 58A VO Transmission Assembly Oper 460 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

59 59A VO Transmission Assembly Oper 470 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 2 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $1.30 $0.17 $1.47 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.47 $1.47 $0.00

60 60A VO Transmission Assembly Oper 480 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

61 61A VO Transmission Assembly Oper 490 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

62 62A VO Transmission Assembly Oper 500 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

150 0 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $0.00 $0.83 $0.83 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.83 $0.83 $0.00

63 63A VO Transmission Assembly Oper 510 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

64 64A VO Transmission Assembly Oper 520 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

65 65A VO Transmission Assembly Oper 530 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

66 66A VO Transmission Assembly Oper 540 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 1 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.65 $0.33 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

67 67A VO Transmission Assembly Oper 550 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

68 68A VO Transmission Assembly Oper 560 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 2 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $1.30 $0.17 $1.47 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.47 $1.47 $0.00

69 69A VO Transmission Assembly Oper 570 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

70 70A VO Transmission Assembly Oper 580 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 2 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $1.30 $0.17 $1.47 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.47 $1.47 $0.00

71 71A VO Transmission Assembly Oper 590 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 2 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $1.30 $0.17 $1.47 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.47 $1.47 $0.00

72 72A VO Transmission Assembly Oper 600 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 72 72A VO Transmission Assembly Oper 600 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 150 0 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $0.00 $0.83 $0.83 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.83 $0.83 $0.00 Transmission Assembly, 

OEM, HC

150 0 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $0.00 $0.83 $0.83 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.83 $0.83 $0.00

73 73A VO Transmission Assembly Oper 610 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

74 74A VO Transmission Assembly Oper 620 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

75 75A VO Transmission Assembly Oper 630 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

76 76A VO Transmission Assembly Oper 640 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

77 77A VO Transmission Assembly Oper 650 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $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 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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)

78 78A VO Transmission Assembly Oper 660 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

79 79A VO Transmission Assembly Oper 670 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

80 80A VO Transmission Assembly Oper 680 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 4 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $2.60 $0.33 $2.93 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.93 $2.93 $0.00

81 81A VO Transmission Assembly Oper 690 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

82 82A VO Transmission Assembly Oper 700 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

83 83A VO Transmission Assembly Oper 710 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

OEM, LMC

84 84A VO Transmission Assembly Oper 720 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

85 85A VO Transmission Assembly Oper 730 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

86 86A VO Transmission Assembly Oper 740 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

87 87A VO Transmission Assembly Oper 750 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

88 88A VO Transmission Assembly Oper 760 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

89 89A VO Transmission Assembly Oper 770 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

90 90A VO Transmission Assembly Oper 780 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

91 91A VO Transmission Assembly Oper 790 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

92 92A VO Transmission Assembly Oper 800 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

93 93A VO Transmission Assembly Oper 810 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 2 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $1.30 $0.17 $1.47 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.47 $1.47 $0.00

94 94A VO Transmission Assembly Oper 820 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 0 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.00 $0.17 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.00

95 95A VO Transmission Assembly Oper 830 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, MHC

150 0 1 1 0.000 $0.00 $97.48 $75.00 $75.00 $0.00 $0.00 $0.50 $0.50 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.50 $0.50 $0.00

96 96A VO Transmission Assembly Oper 840 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

97 97A VO Transmission Assembly Oper 850 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

98 98A VO Transmission Assembly Oper 860 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC 98 98A VO Transmission Assembly Oper 860 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

99 99A VO Transmission Assembly Oper 870 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

100 100A VO Transmission Assembly Oper 880 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

101 101A VO Transmission Assembly Oper 890 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

102 102A VO Transmission Assembly Oper 900 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

103 103A VO Transmission Assembly Oper 910 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LMC

150 1 1 1 0.000 $0.00 $97.48 $25.00 $25.00 $0.00 $0.65 $0.17 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $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: 5 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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)

104 104A VO Transmission Assembly Oper 920 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

105 105A VO Transmission Assembly Oper 930 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

106 106A VO Transmission Assembly Test loop 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

107 107A VO Transmission Assembly Test 10 140300-N0502-01-18 1 Test OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

30 1 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $3.25 $4.17 $7.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $7.42 $7.42 $0.00

108 108A VO Transmission Assembly Test 20 140300-N0502-01-18 1 Test OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

30 0 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $0.00 $4.17 $4.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.17 $4.17 $0.00

109 109A VO Transmission Assembly Test 30 140300-N0502-01-18 1 Test OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

30 1 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $3.25 $4.17 $7.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $7.42 $7.42 $0.00

OEM, HC

110 110A VO Transmission Assembly Test 40 140300-N0502-01-18 1 Test OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

30 0 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $0.00 $4.17 $4.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.17 $4.17 $0.00

111 111A VO Transmission Assembly Test 50 140300-N0502-01-18 1 Test OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, HC

30 1 1 1 0.000 $0.00 $97.48 $125.00 $125.00 $0.00 $3.25 $4.17 $7.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $7.42 $7.42 $0.00

112 112A VO Transmission Assembly Oper 940 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

113 113A VO Transmission Assembly Oper 950 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

114 114A VO Transmission Assembly Oper 960 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

115 115A VO Transmission Assembly Oper 970 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

116 116A VO Transmission Assembly Oper 980 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.65 $0.10 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

117 117A VO Transmission Assembly Oper 990 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

118 118A VO Transmission Assembly Oper 1000 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission 

Assembly, OEM, MC

150 0 1 1 0.000 $0.00 $97.48 $50.00 $50.00 $0.00 $0.00 $0.33 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

119 119A VO Transmission Assembly Oper 1010 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

120 120A VO Transmission Assembly Oper 1020 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

121 121A VO Transmission Assembly Oper 1030 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 2 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $1.30 $0.10 $1.40 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.40 $1.40 $0.00

122 122A VO Transmission Assembly Oper 1040 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

123 123A VO Transmission Assembly Oper 1050 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM Transmission Assembly, 

OEM, LC

150 0 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.00 $0.10 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $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

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

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 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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)

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

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

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 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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)

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

0 $0.00 $0.00 $0.00 $0.00

112 0 $0.00 $0.00 $0.00 $0.00 $0.00

113 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 $102.66

T1 or OEM Total Manufacturing Cost: $0.00 $58.49 $44.17 $102.66 $0.00 $0.00 $0.00 $0.00 $0.00 $102.66

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 $58.49 $44.17 $102.66 $0.00 $0.00 $0.00 $0.00 $0.00 $102.66 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $102.66

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 57 1000 6 56250

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 mus

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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.

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

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: 8 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 Assembly, Mark-up Covered by ICM

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: OE Transmission Assembly Line - Final Part Number: 021300-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

9,375

10

North America

North America

FOB Ship Point

48

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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)

"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: 9 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 VO Transmission Assembly Oper 5 140300-N0502-01-01

2A VO Transmission Assembly Oper 10 140300-N0502-01-02

3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03

4A VO Transmission Assembly Oper 15 140300-N0502-01-04

5A VO Transmission Assembly Oper 20 140300-N0502-01-05

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 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper.5 Auto load case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper. 10 Wassher automation 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper. Off-Line Part washer 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper. 15 Loaad case to assembly pallet 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper. 20 Auto clamp case to pallet and rotate 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 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

6A VO Transmission Assembly Oper 30 140300-N0502-01-06

7A VO Transmission Assembly Oper 40 140300-N0502-01-07

8A VO Transmission Assembly Oper 50 140300-N0502-01-08

9A VO Transmission Assembly Oper 60 140300-N0502-01-09

10A VO Transmission Assembly Oper 70 140300-N0502-01-10

11A VO Transmission Assembly Oper 80 140300-N0502-01-11

12A VO Transmission Assembly Oper 90 140300-N0502-01-12

13A VO Transmission Assembly Oper 100 140300-N0502-01-13

14A VO Transmission Assembly Oper 110 140300-N0502-01-14

15A VO Transmission Assembly Oper 120 140300-N0502-01-15

16A VO Transmission Assembly Oper 130 140300-N0502-01-16

17A VO Transmission Assembly Oper 140 140300-N0502-01-17

18A VO Transmission Assembly Oper 150 140300-N0502-01-18

18A VO Transmission Assembly Oper 160 140300-N0502-01-18

20A VO Transmission Assembly Oper 170 140300-N0502-01-18

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper. 30 Press in traction motor bearing and park lever seal 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper. 40 Press dowels in case for cover and planetary housing, air assemble air 

inlet cover & r/d 1 bolt 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 50 nstall park lever comb & bullet assembly into case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 60 Align rooster comb shaft holes & install pin 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 oper 70 Install 2 park lever springs and r/d spring bolt 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 80 Rotate housing 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 90 Press to case 2 cover dowels & assemble 3 bearing shims to 3 beaing 

bores 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 100 Load & press 2 tapered bearing races 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 110 Load & press 1 tapered bearng race and 1 ball bearing race 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 120 Install bullet receiver sleeve, half round bullet locator, position parking 

pawl arm, parking pawl pivot pin and spring 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 130 position bullet reciever and r/d 2 screws 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 140 Install oil pump assembly, r/d 3 bolts, install short passage tube 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 150 Install ling oil passage tube, mounting bracket, r/d 2 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 160 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 170 Repair bay entrance / exit 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

21A VO Transmission Assembly Oper 180 140300-N0502-01-18

22A VO Transmission Assembly Oper 190 140300-N0502-01-18

23A VO Transmission Assembly Oper 200 140300-N0502-01-18

24A VO Transmission Assembly Oper 210 140300-N0502-01-18

25A VO Transmission Assembly Oper 220 140300-N0502-01-18

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 180 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 190 Rotate case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 200 Install planetary assembly, oil pump drive and planet housing cover 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 210 Start, r/d 7 planetary housing cover bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 220 Position generator spped sensor wire harness thru case opening, 

attach wire to sensor, install speed senor - generator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 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: 10 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

26A VO Transmission Assembly Oper 230 140300-N0502-01-18

27A VO Transmission Assembly Oper 240 140300-N0502-01-18

28A VO Transmission Assembly Oper 250 140300-N0502-01-18

29A VO Transmission Assembly Oper 260 140300-N0502-01-18

30A VO Transmission Assembly Oper 270 140300-N0502-01-18

31A VO Transmission Assembly Oper 280 140300-N0502-01-18

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

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 230 start & r/d 3 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 240 Position 2 generator & motor isolators thru case opening and start, r/d 

2 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 250 position motor speed sensor wire harness thru case and attach to 

sensor

5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 260 Install speed sensor (traction motor) and start, r/d 3 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 270 Install generator assembly, position speed sensor wire clip on bolt 

boss and start, r/d 3 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 280 Install traction motor assembly, position speed sensor wire clip on bolt 

boss and start, r/d 3 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18

33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18

34A VO Transmission Assembly Oper 290 140300-N0502-01-18

35A VO Transmission Assembly Oper 300 140300-N0502-01-18

36A VO Transmission Assembly Oper 310 140300-N0502-01-18

37A VO Transmission Assembly Oper 320 140300-N0502-01-18

38A VO Transmission Assembly Oper 330 140300-N0502-01-18

39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18

40 VO Transmission Assembly Oper 340 140300-N0502-01-18

41A VO Transmission Assembly Oper 350 140300-N0502-01-18

42A VO Transmission Assembly Oper 360 140300-N0502-01-18

43A VO Transmission Assembly Oper 370 140300-N0502-01-18

44A VO Transmission Assembly Oper 380 140300-N0502-01-18

45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18

46A VO Transmission Assembly Oper 390 140300-N0502-01-18

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper off-line gage cover rail to generator and motor bearings pockets / bearings 

and select shim and install in case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper off-line RTV cover 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 290 pick and place cover over dowels to case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$1.30 $0.17 $1.47 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 300 Start and r/d to zero torquw 20 cover bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 310 Auto r/d 20 cover bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 320 Rotate case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 330 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.83 $0.83 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Off-line gage end play and torque to turn 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 340 Repair bay entrance / exit 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 350 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 360 Position traction speed sensor wire clip & r/d 1 bolts, position 

generator speed sensor wire clip & r/d 2 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 370 Install 6 terminal leads thru case and start, r/d 1 bolt per lead 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 380 Position motor and generator wires to terminal leads and start & r/d 1 

bolts per wire 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00

Oper Off-Line Press inner roller bearings into both ends of generator transfer 

shaft, and outer ball bearing to cover side generator transfer shaft and tapered 

bearing to case side

5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 390 Align and press traction motor transfer shaft thru roller bearing in case 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

47A VO Transmission Assembly Oper 400 140300-N0502-01-18

48A VO Transmission Assembly Oper 410 140300-N0502-01-18

49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18

50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18

51A VO Transmission Assembly Oper 420 140300-N0502-01-18

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 390 Align and press traction motor transfer shaft thru roller bearing in case 

and OD spline into traction rotor shaft ID spline 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 400 Press transfer shaft over generator planetary shaft 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 410 Align and assemble differential assembly into case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Off-line press taper bearing on case side of output shaft, press outer gear 

set into transfer gear output shaft 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Off-line press taper bearing on cover side of output shaft, start & r/d 1 nut 

on output shaft 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 420 Install output shaft assemmbly into case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 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: 11 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

52A VO Transmission Assembly Oper 430 140300-N0502-01-18

53A VO Transmission Assembly Oper 440 140300-N0502-01-18

54A VO Transmission Assembly Oper 450 140300-N0502-01-18

55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18

56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18

57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18

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

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 430 Press roller bearing onto traction motor transfer shaft 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 440 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 450 Measure height from case rail to taper bearing race on differential, 

output dhaft and both transfer shafts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.83 $1.48 $0.00 $0.00 $0.00 $0.00 $0.00

Oper off-line, load bell housing, measure cover rail to above mentioned bearing 

pocket depths and select shims and install in cover and load / press 3 races into 

cover

5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Off-line install oil diffuser and start, r/d 3 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 $0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Off-line RTV gear side of bell housing 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

58A VO Transmission Assembly Oper 460 140300-N0502-01-18

59A VO Transmission Assembly Oper 470 140300-N0502-01-18

60A VO Transmission Assembly Oper 480 140300-N0502-01-18

61A VO Transmission Assembly Oper 490 140300-N0502-01-18

62A VO Transmission Assembly Oper 500 140300-N0502-01-18

63A VO Transmission Assembly Oper 510 140300-N0502-01-18

64A VO Transmission Assembly Oper 520 140300-N0502-01-18

65A VO Transmission Assembly Oper 530 140300-N0502-01-18

66A VO Transmission Assembly Oper 540 140300-N0502-01-18

67A VO Transmission Assembly Oper 550 140300-N0502-01-18

68A VO Transmission Assembly Oper 560 140300-N0502-01-18

69A VO Transmission Assembly Oper 570 140300-N0502-01-18

70A VO Transmission Assembly Oper 580 140300-N0502-01-18

71A VO Transmission Assembly Oper 590 140300-N0502-01-18

72A VO Transmission Assembly Oper 600 140300-N0502-01-18

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Off-line RTV gear side of bell housing 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 460 Auto place bell housing over dowels on case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$1.30 $0.17 $1.47 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 470 Start and r/d to zero torque 21 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 480 Auto r/d 21 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 490 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.83 $0.83 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 500 Torque to turn output shaft 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 510 Repair bay entrance / exit 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 520 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 530 rotate case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.33 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 540 install seal in output shaft bores on both side of case and install input 

shaft seal to bell housing side 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 550 Rotate case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$1.30 $0.17 $1.47 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 560 Install oil cooler gasket, oil cooler cover and start, r/d 19 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 570 Install 2 dowels and electronic housing gasket 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$1.30 $0.17 $1.47 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 580 Position electronic housing over dowels 7 start 2 bolts, start, r/d to 

zero torque 10 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$1.30 $0.17 $1.47 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 590 Start and r/d to zero torque 20 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

72A VO Transmission Assembly Oper 600 140300-N0502-01-18 $0.00 $0.83 $0.83 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 600 Auto r/d 32 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

73A VO Transmission Assembly Oper 610 140300-N0502-01-18

74A VO Transmission Assembly Oper 620 140300-N0502-01-18

75A VO Transmission Assembly Oper 630 140300-N0502-01-18

76A VO Transmission Assembly Oper 640 140300-N0502-01-18

77A VO Transmission Assembly Oper 650 140300-N0502-01-18

$0.00 $0.83 $0.83 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 600 Auto r/d 32 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 oper 610 Install 2 current sensor bars over terminal leads, start & r/d 2 bolts into 

each current sensor 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 620 Install traction motor control unit & r/d 6 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 630 Install generator control unit & r/d 6 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 640 Install Denso control unit & r/d 4 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 650 Install 3 bus bars between traction control unit and current sensor bar 

& r/d 2 bolts each 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 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: 12 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

78A VO Transmission Assembly Oper 660 140300-N0502-01-18

79A VO Transmission Assembly Oper 670 140300-N0502-01-18

80A VO Transmission Assembly Oper 680 140300-N0502-01-18

81A VO Transmission Assembly Oper 690 140300-N0502-01-18

82A VO Transmission Assembly Oper 700 140300-N0502-01-18

83A VO Transmission Assembly Oper 710 140300-N0502-01-18

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

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 660 Install 3 bus bars between generator control unit and sensor bar & r/d 

2 bolts each 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 670 Route all wires off control units before install cover then install wire 

harness into each control unit 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$2.60 $0.33 $2.93 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Off-line Main Control build up loop 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 690 Install main control start & r/d 6 bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 700 Fasten 3 wire clips and insert 4 wire connectors to circuit board 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 710 Install short bar, start, r/d nut / bolt 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

84A VO Transmission Assembly Oper 720 140300-N0502-01-18

85A VO Transmission Assembly Oper 730 140300-N0502-01-18

86A VO Transmission Assembly Oper 740 140300-N0502-01-18

87A VO Transmission Assembly Oper 750 140300-N0502-01-18

88A VO Transmission Assembly Oper 760 140300-N0502-01-18

89A VO Transmission Assembly Oper 770 140300-N0502-01-18

90A VO Transmission Assembly Oper 780 140300-N0502-01-18

91A VO Transmission Assembly Oper 790 140300-N0502-01-18

92A VO Transmission Assembly Oper 800 140300-N0502-01-18

93A VO Transmission Assembly Oper 810 140300-N0502-01-18

94A VO Transmission Assembly Oper 820 140300-N0502-01-18

95A VO Transmission Assembly Oper 830 140300-N0502-01-18

96A VO Transmission Assembly Oper 840 140300-N0502-01-18

97A VO Transmission Assembly Oper 850 140300-N0502-01-18

98A VO Transmission Assembly Oper 860 140300-N0502-01-18

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 720 install medium bar, start, r/d nut / bolt 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 oper 730 Install long bar, start, r/dnut /bolts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 740 Connect & r/d wires to lower black box 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 750 Install TACM connector to electronic housing, insert wire thru hole, 

start & r/d 3 bolts and terminate 2 wires to stud & r/d 2 nuts 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 760 Install 2 TACM #2 connectors and r/d 1 bolt each 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 770 Install large harness guide, start & r/d 4 screws 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 780 Install 5 harness clips to harness guide, r/d ground stud 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 790 Ppsition 3 wire harness with 7 connectors, terminate / plug in 9 

connectors includes 2 existing connectors 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 800 Install cork gasket to electronic housing 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$1.30 $0.17 $1.47 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 810 Position cover & tab assembly, start & r/d to zero torque 2 studs 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.17 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 820 Install & r/d to zero torque 18 bolts and 4 studs 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.50 $0.50 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 830 Auto r/d 22 fasteners 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 840 Rotate case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 850 Install shift lever indicator, lever, locking clamp, r/d 2 bolts, 1 stud 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

98A VO Transmission Assembly Oper 860 140300-N0502-01-18 $0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 860 Install & r/d 2 studs w/ nuts, 2 coolant outlets and 1 temp sensor 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

99A VO Transmission Assembly Oper 870 140300-N0502-01-18

100A VO Transmission Assembly Oper 880 140300-N0502-01-18

101A VO Transmission Assembly Oper 890 140300-N0502-01-18

102A VO Transmission Assembly Oper 900 140300-N0502-01-18

103A VO Transmission Assembly Oper 910 140300-N0502-01-18

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 860 Install & r/d 2 studs w/ nuts, 2 coolant outlets and 1 temp sensor 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 870 Rotate case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 880 Install & r/d small plug w/O-ring, 2 large plugs w/ O-ring and press in 

small coolant port 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 890 Feed & press vent tube and install rubber hose w/ clip 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 900 Rotate case 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.17 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 910 Install & r/d 3 large studs, drain plug and cover plug 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 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: 13 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

104A VO Transmission Assembly Oper 920 140300-N0502-01-18

105A VO Transmission Assembly Oper 930 140300-N0502-01-18

106A VO Transmission Assembly Test loop 140300-N0502-01-18

107A VO Transmission Assembly Test 10 140300-N0502-01-18

108A VO Transmission Assembly Test 20 140300-N0502-01-18

109A VO Transmission Assembly Test 30 140300-N0502-01-18

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 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 920 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 930 Load test loop 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Test loop 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$3.25 $4.17 $7.42 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Test 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 120 1.0 1.0

$0.00 $4.17 $4.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Test 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 120 1.0 1.0

$3.25 $4.17 $7.42 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Test 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 120 1.0 1.0

110A VO Transmission Assembly Test 40 140300-N0502-01-18

111A VO Transmission Assembly Test 50 140300-N0502-01-18

112A VO Transmission Assembly Oper 940 140300-N0502-01-18

113A VO Transmission Assembly Oper 950 140300-N0502-01-18

114A VO Transmission Assembly Oper 960 140300-N0502-01-18

115A VO Transmission Assembly Oper 970 140300-N0502-01-18

116A VO Transmission Assembly Oper 980 140300-N0502-01-18

117A VO Transmission Assembly Oper 990 140300-N0502-01-18

118A VO Transmission Assembly Oper 1000 140300-N0502-01-18

119A VO Transmission Assembly Oper 1010 140300-N0502-01-18

120A VO Transmission Assembly Oper 1020 140300-N0502-01-18

121A VO Transmission Assembly Oper 1030 140300-N0502-01-18

122A VO Transmission Assembly Oper 1040 140300-N0502-01-18

123A VO Transmission Assembly Oper 1050 140300-N0502-01-18

Purchase Part - High Impact Item (Full Cost Mapping)

$0.00 $4.17 $4.17 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Test 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 120 1.0 1.0

$3.25 $4.17 $7.42 $0.00 $0.00 $0.00 $0.00 $0.00 Oper Test 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 120 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 940 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 950 Unload test loop 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 960 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 970 Auto oli fill 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.65 $0.10 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 980 Install & r/d long plug 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 990 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.33 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 1000 Case washer 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 1010 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 1020 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$1.30 $0.10 $1.40 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 1030 Unload to rack 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 1040 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

$0.00 $0.10 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Oper 1050 Powered accumulator 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

Purchase Part - High Impact Item (Full Cost Mapping)

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

$0.00 $0.00 $0.00 $0.00 $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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 14 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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: 15 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

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

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

$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

$58.49 $44.17 $102.66 $0.00 $0.00 $0.00 $0.00 $0.00

$102.66

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: 16 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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: 17 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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 VO Transmission Assembly Oper 5 140300-N0502-01-01

2A VO Transmission Assembly Oper 10 140300-N0502-01-02

3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03

4A VO Transmission Assembly Oper 15 140300-N0502-01-04

5A VO Transmission Assembly Oper 20 140300-N0502-01-05

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

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

6A VO Transmission Assembly Oper 30 140300-N0502-01-06

7A VO Transmission Assembly Oper 40 140300-N0502-01-07

8A VO Transmission Assembly Oper 50 140300-N0502-01-08

9A VO Transmission Assembly Oper 60 140300-N0502-01-09

10A VO Transmission Assembly Oper 70 140300-N0502-01-10

11A VO Transmission Assembly Oper 80 140300-N0502-01-11

12A VO Transmission Assembly Oper 90 140300-N0502-01-12

13A VO Transmission Assembly Oper 100 140300-N0502-01-13

14A VO Transmission Assembly Oper 110 140300-N0502-01-14

15A VO Transmission Assembly Oper 120 140300-N0502-01-15

16A VO Transmission Assembly Oper 130 140300-N0502-01-16

17A VO Transmission Assembly Oper 140 140300-N0502-01-17

18A VO Transmission Assembly Oper 150 140300-N0502-01-18

18A VO Transmission Assembly Oper 160 140300-N0502-01-18

20A VO Transmission Assembly Oper 170 140300-N0502-01-18

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 -

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 -

150 24.00 -

21A VO Transmission Assembly Oper 180 140300-N0502-01-18

22A VO Transmission Assembly Oper 190 140300-N0502-01-18

23A VO Transmission Assembly Oper 200 140300-N0502-01-18

24A VO Transmission Assembly Oper 210 140300-N0502-01-18

25A VO Transmission Assembly Oper 220 140300-N0502-01-18

150 24.00 -

150 24.00 -

150 24.00 1.00

150 24.00 1.00

150 24.00 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: 18 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

26A VO Transmission Assembly Oper 230 140300-N0502-01-18

27A VO Transmission Assembly Oper 240 140300-N0502-01-18

28A VO Transmission Assembly Oper 250 140300-N0502-01-18

29A VO Transmission Assembly Oper 260 140300-N0502-01-18

30A VO Transmission Assembly Oper 270 140300-N0502-01-18

31A VO Transmission Assembly Oper 280 140300-N0502-01-18

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18

33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18

34A VO Transmission Assembly Oper 290 140300-N0502-01-18

35A VO Transmission Assembly Oper 300 140300-N0502-01-18

36A VO Transmission Assembly Oper 310 140300-N0502-01-18

37A VO Transmission Assembly Oper 320 140300-N0502-01-18

38A VO Transmission Assembly Oper 330 140300-N0502-01-18

39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18

40 VO Transmission Assembly Oper 340 140300-N0502-01-18

41A VO Transmission Assembly Oper 350 140300-N0502-01-18

42A VO Transmission Assembly Oper 360 140300-N0502-01-18

43A VO Transmission Assembly Oper 370 140300-N0502-01-18

44A VO Transmission Assembly Oper 380 140300-N0502-01-18

45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18

46A VO Transmission Assembly Oper 390 140300-N0502-01-18

150 24.00 1.00

150 24.00 1.00

150 24.00 -

150 24.00 2.00

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

46A VO Transmission Assembly Oper 390 140300-N0502-01-18 150 24.00 1.00

47A VO Transmission Assembly Oper 400 140300-N0502-01-18

48A VO Transmission Assembly Oper 410 140300-N0502-01-18

49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18

50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18

51A VO Transmission Assembly Oper 420 140300-N0502-01-18

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 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: 19 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

52A VO Transmission Assembly Oper 430 140300-N0502-01-18

53A VO Transmission Assembly Oper 440 140300-N0502-01-18

54A VO Transmission Assembly Oper 450 140300-N0502-01-18

55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18

56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18

57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

150 24.00 1.00

150 24.00 -

150 24.00 -

150 24.00 1.00

150 24.00 1.00

57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 150 24.00 1.00

58A VO Transmission Assembly Oper 460 140300-N0502-01-18

59A VO Transmission Assembly Oper 470 140300-N0502-01-18

60A VO Transmission Assembly Oper 480 140300-N0502-01-18

61A VO Transmission Assembly Oper 490 140300-N0502-01-18

62A VO Transmission Assembly Oper 500 140300-N0502-01-18

63A VO Transmission Assembly Oper 510 140300-N0502-01-18

64A VO Transmission Assembly Oper 520 140300-N0502-01-18

65A VO Transmission Assembly Oper 530 140300-N0502-01-18

66A VO Transmission Assembly Oper 540 140300-N0502-01-18

67A VO Transmission Assembly Oper 550 140300-N0502-01-18

68A VO Transmission Assembly Oper 560 140300-N0502-01-18

69A VO Transmission Assembly Oper 570 140300-N0502-01-18

70A VO Transmission Assembly Oper 580 140300-N0502-01-18

71A VO Transmission Assembly Oper 590 140300-N0502-01-18

72A VO Transmission Assembly Oper 600 140300-N0502-01-18

150 24.00 1.00

150 24.00 -

150 24.00 2.00

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 1.00

150 24.00 -

150 24.00 2.00

150 24.00 1.00

150 24.00 2.00

150 24.00 2.00

72A VO Transmission Assembly Oper 600 140300-N0502-01-18 150 24.00 -

73A VO Transmission Assembly Oper 610 140300-N0502-01-18

74A VO Transmission Assembly Oper 620 140300-N0502-01-18

75A VO Transmission Assembly Oper 630 140300-N0502-01-18

76A VO Transmission Assembly Oper 640 140300-N0502-01-18

77A VO Transmission Assembly Oper 650 140300-N0502-01-18

150 24.00 -

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 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: 20 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

78A VO Transmission Assembly Oper 660 140300-N0502-01-18

79A VO Transmission Assembly Oper 670 140300-N0502-01-18

80A VO Transmission Assembly Oper 680 140300-N0502-01-18

81A VO Transmission Assembly Oper 690 140300-N0502-01-18

82A VO Transmission Assembly Oper 700 140300-N0502-01-18

83A VO Transmission Assembly Oper 710 140300-N0502-01-18

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

150 24.00 1.00

150 24.00 1.00

150 24.00 4.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

84A VO Transmission Assembly Oper 720 140300-N0502-01-18

85A VO Transmission Assembly Oper 730 140300-N0502-01-18

86A VO Transmission Assembly Oper 740 140300-N0502-01-18

87A VO Transmission Assembly Oper 750 140300-N0502-01-18

88A VO Transmission Assembly Oper 760 140300-N0502-01-18

89A VO Transmission Assembly Oper 770 140300-N0502-01-18

90A VO Transmission Assembly Oper 780 140300-N0502-01-18

91A VO Transmission Assembly Oper 790 140300-N0502-01-18

92A VO Transmission Assembly Oper 800 140300-N0502-01-18

93A VO Transmission Assembly Oper 810 140300-N0502-01-18

94A VO Transmission Assembly Oper 820 140300-N0502-01-18

95A VO Transmission Assembly Oper 830 140300-N0502-01-18

96A VO Transmission Assembly Oper 840 140300-N0502-01-18

97A VO Transmission Assembly Oper 850 140300-N0502-01-18

98A VO Transmission Assembly Oper 860 140300-N0502-01-18

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 2.00

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 1.00

98A VO Transmission Assembly Oper 860 140300-N0502-01-18 150 24.00 1.00

99A VO Transmission Assembly Oper 870 140300-N0502-01-18

100A VO Transmission Assembly Oper 880 140300-N0502-01-18

101A VO Transmission Assembly Oper 890 140300-N0502-01-18

102A VO Transmission Assembly Oper 900 140300-N0502-01-18

103A VO Transmission Assembly Oper 910 140300-N0502-01-18

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 1.00

150 24.00 -

150 24.00 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: 21 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

104A VO Transmission Assembly Oper 920 140300-N0502-01-18

105A VO Transmission Assembly Oper 930 140300-N0502-01-18

106A VO Transmission Assembly Test loop 140300-N0502-01-18

107A VO Transmission Assembly Test 10 140300-N0502-01-18

108A VO Transmission Assembly Test 20 140300-N0502-01-18

109A VO Transmission Assembly Test 30 140300-N0502-01-18

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

150 24.00 -

150 24.00 -

150 24.00 -

30 120.00 1.00

30 120.00 -

30 120.00 1.00

110A VO Transmission Assembly Test 40 140300-N0502-01-18

111A VO Transmission Assembly Test 50 140300-N0502-01-18

112A VO Transmission Assembly Oper 940 140300-N0502-01-18

113A VO Transmission Assembly Oper 950 140300-N0502-01-18

114A VO Transmission Assembly Oper 960 140300-N0502-01-18

115A VO Transmission Assembly Oper 970 140300-N0502-01-18

116A VO Transmission Assembly Oper 980 140300-N0502-01-18

117A VO Transmission Assembly Oper 990 140300-N0502-01-18

118A VO Transmission Assembly Oper 1000 140300-N0502-01-18

119A VO Transmission Assembly Oper 1010 140300-N0502-01-18

120A VO Transmission Assembly Oper 1020 140300-N0502-01-18

121A VO Transmission Assembly Oper 1030 140300-N0502-01-18

122A VO Transmission Assembly Oper 1040 140300-N0502-01-18

123A VO Transmission Assembly Oper 1050 140300-N0502-01-18

Purchase Part - High Impact Item (Full Cost Mapping)

30 120.00 -

30 120.00 1.00

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 1.00

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 -

150 24.00 2.00

150 24.00 -

150 24.00 -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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: 22 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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: 23 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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.

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

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: 24 of 24 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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
HEV Transmission

Time 

(sec)

Levels of 

complexity

Man 

Station

Auto 

station

Base 

Equipment 

Category 

Item 

Number

Equipment 

category 

Item 

Number

Number 

of r/d 

units

Spindle # 

per r/d 

unit (5L)

# of 

pressed 

parts 

(9B/9D)

Oper.# Sta.# Assembly Process Reference Photos

5 Load Load Case to washer pallet 26 M 1 4 4E

10 Auto Washer automation L 1 10 10C

Off-line Part washer M 1 10 10A

 

15 Unload / load Load case to assembly pallet over pins M 1 4 4E

20 Auto Clamp case and rotate to electric box side up L 1 2 5H 1 2

30 Semi- auto Press in Traction motor bearing M 1 1 9D 2

Press in Park lever seal 

40 Manual Press in 2 locating dowels for Cover and 2 dowels for Planetary set housing M 1 1 9E 4

Assemble air inlet cover 5A 1 1

Start & rundown (1) bolt

50 Manual Place Park lever rooster comb & bullet assy. Into case L 1 1

Install Park lever shaft thru housing and into rooster comb

60 Manual Hand align rooster comb shaft holes & install pin with pin press tool L 1 1 9E

70 Manual Install 2 park lever springs and run down spring bolt L 1 1 5A 1 1

80 Rotate Rotate housing to gear box side up L 1 052

90 Press in 2 cover mounting dowels L 1 1 9E 2

Assemble 3 bearing shims to 3 bearing bores (all except main transfer gear 

bore)

100 Semi-auto Load and press 2 tapered bearing races (all except traction motor bore) M 1 1 9D 2

110 Semi-auto Load and press 1 tapered bearing races (all except traction motor bore) M 1 1 9D 2

Load and press 1 ball bearing race into case traction motor bore

120 Manual Install bullet receiver sleeve L 1 1

Install half round bullet locator

Position to install parking pawl arm

Install parking pawl arm pivot pin with spring

130 Manual Position to install bullet receiver L 1 1 5A 1

Start & rundown 2 bullet receiver mounting screws

140 Manual Position to install oil pump assembly L 1 1 5A 1

Start & rundown 3 oil pump assembly mounting bolts

Install short trans passage tube 0587

150 Manual Install long oil pump tube L 1 1 5A 1

1 of 7
Position 2 tube mounting brackets

Start & rundown 2 long oil pump bracket mounting bolts

160

On-line 

accumulator Powered roller section L 1 051

170 Auto Repair bay entrance / exit L 1 05

180

On-line 

accumulator Powered roller section L 1 051

190 Rotate Rotate case to electric box side up L 1 052

200 Manual Install planetary assembly 3856 L 1 1

Install oil pump drive assembly 3852

Install planetary housing cover 3848

210 Manual Place, start & rundown 7 planetary housing cover mounting bolts L 1 1 5A 1

220 Manual Poisition generator speed sensor wire harness thru case opening 3681 L 1 1

Attach wire harness to sensor

Install speed sensor - Generator 3826

230 Manual Place, start & rundown 3 bolts L 1 1 5A 1

240 Manual Position (2) generator & motor isolators (at pass thru case) L 1 1 5A 1

Place, start & rundown 2 bolts 

250 Manual Poisition motor speed sensor wire harness thru case opening L 1 1

Attach wire harness to sensor

260 Manual Install speed sensor - Traction Motor 3826 L 1 1 5A 1

Place, start & rundown 3 bolts

270 Manual Install generator assembly with terminal wires down 3807 L 1 1 5A 2

Poisition speed sensor wire clip on (1) bolt boss before rundown

Place, start & rundown 3 bolts

280 Manual Install traction motor assembly with terminal wires down 3807 L 1 1 5A 1

Poisition speed sensor wire clip on (1) bolt boss before rundown

Place, start & rundown 3 bolts

Off-line Manual - Load cover to gage station L 1 7 7B

Gage Station Measure case rail to generator and motor (2) bearings

Measure cover rail to (2) bearing pockets (depth)

Manual - Select shims grease and install in cover

Off-line RTV cover L 1 6 6A

290 On-Line Pick, rotate and place cover over dowels to electric motor side of case L 1 052

300 Manual Place, start & rundown 10 cover mounting bolts L 2 1

Manual Place, start & rundown 10 cover mounting bolts

2 of 7
310 Auto R/d 20 cover bolts/studs M 1 2 5K 1 20

320 Rotate Rotate housing to gear box side up L 1 052

330

On-line 

accumulator Powered roller section L 1 051

Gage Station

Check for no end play condition and torque to turn on generator and motor 

shafts 3803 H 1 7 7D

340 Manual Repair bay entrance / exit L 1 05

350

On-line 

accumulator Powered roller section L 1 051

360 Manual Poisition traction speed sensor wire clip on (1) bolt boss before rundown L 1 1 5A 1

Place, start & rundown 1 bolt

Poisition motor speed sensor wire clip bracket on (2) bolt bosses before 

rundown

Place, start & rundown 2 bolts

Attach motor speed sensor wire connector clip to bracket 3765

370 Manual Install (6) terminal leads thru case 3757 L 1 1 5A 1

Place, start & rundown 1 bolt per lead

380 Manual Position motor & generator wires to terminal leads 3757 L 1 1 5A 1

Place, start & rundown 1 bolt per wire

Off-line Manual load semi-auto press stations M 1 1 9D 2

Press inner roller bearings into both ends generator transfer shaft

Press outer ball bearing on cover side generator transfer shaft and tapered 

bearing on case side

390 Semi-auto

Align and press traction motor transfer shaft thru roller bearing in case then 

OD spline into traction rotor shaft ID spline M 1 1 9D 2

400 Semi-auto Press transfer shaft over the generator planetary shaft M 1 1 9C

410 Manual

Align and assemble diferential assembly into case (roller bearing into race in 

case) L 1 1

Offline Manual load semi-auto press station

Press taper bearing on case side of output shaft 

Press outer gear set onto transfer gear output shaft 

Offline Manual load semi-auto press station

Press taper bearing on cover side of output shaft 

Place, start & rundown 1 nut on end of output shaft

420 Manual Install output shaft aseembly into case (roller bearing into race) 3782/3751 L 1 1

430 Semi-auto Press roller bearing on to traction motor transfer shaft (cover side) 3780 L 1 1 9C

440

On-line 

accumulator Powered roller section L 1 051

3 of 7
450

Gage Station 

online

Measure height from case rail to taper bearing race on differential, output & 

transfer shafts H 1 7 7B

Gage Station Manual - Load bell housing to gage station H 1 7 7C

Offline Measure from cover rail to above mentioned (3) bearing pockets (depth)

Dial Machine Manual - Select shims and install in cover then load 3 races

Semi-auto - Press (3) races into cover

Off- line Manual L 1 1 5A 1

Install oil diffuser 

Place, start & rundown 3 bolts

Off-line RTV gear side of Bell housing M 1 1 6A

460 Auto Pick, rotate and place bell housing over dowels to gear side of case M 1 1 3D

470 Manual Place, start 11 bolts (bell housing to gear side of case) L 2 1

Manual Place, start 10 bolts (bell housing to gear side of case)

480 Auto Rundown 21 bolts M 1 1 5K 1 21

490

On-line 

accumulator Powered roller section L 1 051

500 Online Automatic torque to turn output shaft H 1 1 7D

Gage Station

510 Manual Repair bay entrance / exit L 1 05

520

On-line 

accumulator Powered roller section L 1 051

530 Rotate Case Electronic face down L 1 052

540 Semi-Auto Install seal in output shaft bores on bell housing side and gear box side M 1 1 9D 3

Install seal in input shaft bore on bell housing side

550 Rotate Case Electronic face up L 1 052

560 Manual Install oil cooler gasket 3701 L 2 1 5A 2

Install oil cooler cover

Place, start & rundown 19 bolts

570 Manual Install (2) dowels L 1 1 9D

Install electronic housing gasket 3696

580 Manual Position electronic housing over dowels in case & start two bolts L 2 1 5A 1

Manual Place, start 10 bolts (electronic housing to case)

590 Manual Place, start 10 bolts (electronic housing to case) L 2 1 5A 2

Manual Place, start 10 bolts (electronic housing to case)

600 Auto Rundown 32 bolts (electronic housing to case) H 1 2 5K 2

4 of 7
610 Manual Install (2) current sensor bars over terminal leads L 1 1 5A 1

Place, start & rundown 2 bolts into each current sensor 3683, 3674

620 Manual Install traction motor control unit and r/d 6 bolts 3627 L 1 1 5A 1

630 Manual Install generator control unit and r/d 6 bolts 3627 L 1 1 5A 1

640 Manual Install (Denso) control unit and r/d 4 bolts 3627 L 1 1 5A 1

650 Manual Install (3) bus bars between traction control unit and current sensor bar 3627 L 1 1 5A 1

Rundown 2 bolts each

660 Manual Install (3) bus bars between generator control unit and sensor bar 3627 L 1 1 5A 1

Rundown 2 bolts each

670 Manual Route all wires coming off control units before installing cover L 1 1

Install wire harnesses into each of the traction & generator control units

680 Offline Main control housing build loop L 4 11 11A

1 - Load housing to fixture and install capacitor box

2 - Place, start & rundown 8 screws 

3 - Rotate control unit housing to top side up and install 2 black box

4 - Place, start & rundown 3 screws each box

5 - Install (1) green circuit board and r/d 6 screws

6 - Rundown (6) screws into curcuit board and install harness brackets

7 - Rundown 4 bracket screws and mount wire clips

8 - unload main control assembly 3625

690 Manual Install main control unit housing 3623 L 1 1 5A 1

Place, start & rundown 6 bolts

700 Manual Fasten (3) wires into clips and insert (4) wire connectors into curcuit board L 1 1

710 Manual

Install Short bar - Install left hand hole over right hand stud w/nut at upper 

box ? (with wire) and right hand hole goes over left stud w/nut on lower box 

and r/d nuts 3581 L 1 1 5A 1

720 Manual

install Medium bar - Install left hand & center hole to lower box ? w/ 2 bolts, 

and right hand hole goes over left stud w/nut on upper box and r/d 3581 L 1 1 5A 1

730 Manual

Long bar - Install right hand hole over lower box right stud w/nut and left hand 

hole w/bolt and r/d 3581 L 1 1 5A 1

740 Manual Connect (1) wire to lower black control box on left lower lug with bolt L 1 1 5A 1

Connect (1) wire to lower black control box on right lower lug with bolt 3607

Place, start & rundown 2 bolts

Place, start & rundown 2 bolts at lugs to connect upper to lower black box 3581

L 1 1 5A 2

750 Manual

Install Main Power TACM connector (orange) to end of electronics housing, 

insert wiring thru holes in housing and position connector 3517

Place, start & rundown 3 bolts

5 of 7
Terminate (2) wires to studs 

Place, start & rundown 2 nuts

760 Manual Install (2) TACM#2 connectors L 1 1 5A 1

Place, start & rundown 1 bolt each 3509

770 Manual Install large harness guide 

Place, start & rundown 4 screws 3518 L 1 1 5A 1

780 Manual Insert (5) harness clips to harness guide 

Install and rundown Ground Stud with nut

790 Manual Position (3) wire harnesses with (7) connectors L 1 1 5A 1

Terminate/plug in (9) connectors (includes 2 existing connectors) 3516, 3518

800 Manual Install cork gasket on top of electronic housing L 1 1

810 Manual Position Cover & Tab Assembly and start and r/d to zero torqe 2 studs bolts L 1 1 5A 1

820 Manual Place, start & rundown to zero torque 8 bolts & 2 stud bolts L 2 1 5A 2

Manual Place, start & rundown to zero torque 8 bolts & 2 stud bolts

830 Auto Auto rundown 22 fasteners M 1 1 5K 22

840 Rotate Rotate pallet to shift lever area L 1 052

850 Manual Install Shift lever indicator housing L 1 1 5A 1

Place, start & rundown 2 bolts 3511

Install Shift Lever/Locking Clamp 

Place, start & rundown 1 nut

860 Manual Install and rundown (2) Studs with nuts L 1 1 5A 2

Install & rundown (2) Coolant Outlets

Install & rundown (1) Temperature Sensor 3510, 3511

870 Rotate 180 Rotate pallet 180 Degrees L 1 052

880 Manual Install & rundown Small Plug w/O-Ring (rear cover) L 1 1 5A 1

Press in Small Coolant Port 3507

Install & rundown (2) Large Torques Plug w/O-Ring (cover)

890 Manual Feed and press Vent Tube and install Rubber Hose with clip L 1 1 9E

3507

900 Rotate 180 Differential end up L 1 052

910 Manual Install and rundown (3) Large A Studs (Torques) on rear of cover L 1 1 5A 3

Install and rundown Drain Plug (Plug Wide) 

Install and rundown Cover Plug (Plug Wide) 

920

On-line 

accumulator Powered roller section L 1 051

930 Auto Load to test loop M 1 4 4E

6 of 7
Automation L 2 1 051

Test Test loop Automation L 5 1 051

Rotate L 1 052

T10 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051

Rotate L 2 052

T20 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051

Rotate L 2 052

T30 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051

Rotate L 2 052

T40 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051

Rotate L 2 052

T50 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051

Rotate L 2 052

940

On-line 

accumulator Powered roller section L 1 051

950 Auto Load from test loop automation M 1 4 4E

Automation L 2 1 051

960

On-line 

accumulator Powered roller section L 2 051

970 Auto Final oil fill H 1 7 7J

980 Manual Install and rundown Long Plug L 1 1 5A 1

990

On-line 

accumulator Powered roller section L 2 051

1000 Auto Wash system H 1 10 10B

1010

On-line 

accumulator Powered roller section L 1 051

1020

On-line 

accumulator Powered roller section L 1 051

1030 Manual Unload to shipping dunnage M 1 1 4G

1040

On-line 

accumulator Powered roller section L 1 051

1050

On-line 

accumulator Powered roller section L 1 051

7 of 7
$

Z.

Generic 36" x 36" pallet, (3 per section) 4 feet wide in floor 

transport. 1/2 Idle station, pre-station, work station, empty 

station and 1/2 idle station. 14' overall length. Overall floor 

space to be 10' wide (2' to contain panel, 4' line width, 4' 

work 

Z.05 Z.05 Transport Corners, cross transfers 4 feet wide in floor transport x 4 feet long. 16 square feet 285,000

Z.051 Z.051 Transport Straight automation with pallet 

stops / controllers

4 feet wide in floor transport x 10 feet long. 40 square feet 

with 3 pallet stops and level controllers 124,000

Z.052 Z.052 Transport Rotate

4 feet wide in floor transport x 6 feet long. Automation 

capable of rotating pallet as required. 24 square feet 165,000

Z.1 Z.1 Manual Work Station Single work station to 

assemble part / parts

Pre-stop, station stop, idle 10 ' feet of transfer automation, 

control panel with part status lights and release button. 

Includes 2 pallets

140,000

Z.2 Z.2 Auto Work Station Single work station to 

assemble part / parts

4 feet wide in floor transport. 1/2 Idle station, pre-station, 

work station, empty station and 1/2 idle station. 14' overall 

length. Overall floor space to be 12' wide (3' to contain panel, 

4' line width, 5' work space) by 14' long - 188 square feet and 

i

202,000

OEM Transmission Assembly 

Equipment

Primary 

Equipment 

Cost Item Equipment Category Name Equipment Description Equipment Specification
Z.3 Z.3

Dedicated Part Handling 

Equipment (e.g. Pick 

and Place)

3A 3A Vertical and Lateral 

Movement (0-10lbs)

Light weight part pick up and 

load to palletized assembly Overhead frame with linear vertical / horizontal movement. 50,000

3B 3B

Vertical, Lateral, Single 

Axis Rotation Movement 

(0-10lbs)

Light weight part pick up, 

rotate and place to palletized 

assembly

Overhead frame with linear vertical / horizontal / rotational 

movement.

65,000

3C 3C Vertical and Lateral 

Movement (11-40lbs)

Medium weight part pick up 

and load to palletized assembly Overhead frame with linear vertical / horizontal movement. 60,000

3D 3D

Vertical, Lateral, Single 

Axis Rotation Movement 

(11-40lbs)

Medium weight part pick up, 

rotate and place to palletized 

assembly

Overhead frame with linear vertical / horizontal / rotational 

movement.

75,000

3E 3E Vertical and Lateral 

Movement (40+lbs)

Heavy weight part pick up and 

load to palletized assembly Overhead frame with linear vertical / horizontal movement. 80,000

3F 3F

Vertical, Lateral, Single 

Axis Rotation Movement 

(40+lbs)

Heavy weight part pick up, 

rotate and place to palletized 

assembly

Overhead frame with linear vertical / horizontal / rotational 

movement.

100,000

4 4

Part Handling 

Equipment 

4A 4A Robotic Handling 

Equipment (0-5lbs) Multi-positional movement Overhead frame or stand alone base with multi-positional movement.

75,000

4B 4B Robotic Handling 

Equipment (5-10) Multi-positional movement Overhead frame or stand alone base with multi-positional movement.

75,000

4C 4C Robotic Handling 

Equipment (10-20lbs) Multi-positional movement Overhead frame or stand alone base with multi-positional movement.

134,000

4D 4D Robotic Handling 

Equipment (20-45) Multi-positional movement Overhead frame or stand alone base with multi-positional movement.

186,000

4E 4E Robotic Handling 

Equipment (45-75) Multi-positional movement Overhead frame or stand alone base with multi-positional movement.

270,000
4F 4F Robotic Handling 

Equipment (75-150) Multi-positional movement Overhead frame or stand alone base with multi-positional movement.

321,000

4G 4G Manual Handling 

Equipment (75-250) Multi-positional movement Overhead frame with fixed-positional movement manually controlled 89,000

5 5 Fastening Equipment

5A 5A Single Spindle -pneumatic 

- Manual Hand controlled pneumatic spindleTool holding rack or overhead fixture with balancer. 15,000

5B 5B Single Spindle -pneumatic 

- semi- auto Manual push button started pneumatic spindle Horizontal, vertical or angular fixture / frame. Tool is manual started with push buttons - auto release. 22,000

5C 5C Single Spindle -pneumatic 

- auto

Automatic station Horizontal, vertical or angular fixture / frame. Auto started 

and released 55,000

5D 5D Single Spindle - Electric - 

Manual Hand controlled electric spindle Tool holding rack or overhead fixture with balancer. 18,000

5E 5E Single Spindle - Electric - 

semi-auto

Manual push button started 

electric spindle

Horizontal, vertical or angular fixture / frame. Tool is manual 

started with push buttons - auto release. 25,000

5F 5F Single Spindle - Electric - 

auto

Automatic station Horizontal, vertical or angular fixture / frame. Auto started 

and released 55,000

5G 5G Multi Spindle -pneumatic - 

semi auto Manual push button started pneumatic spindle Horizontal, vertical or angular fixture / frame. Tool is manual started with push buttons - auto release. 40,000

5H 5H Multi Spindle -pneumatic - 

auto

Automatic station Horizontal, vertical or angular fixture / frame. Auto started 

and released 55,000

5J 5J Multi Spindle - Electric - 

semi-auto

Manual push button started 

electric spindle

Horizontal, vertical or angular fixture / frame. Tool is manual 

started with push buttons - auto release. 40,000

5K 5K Multi Spindle - Electric - 

auto

Automatic station Horizontal, vertical or angular fixture / frame. Auto started 

and released 55,000

5L 5L Multiple parts cost Additional cost per spindle 22,000

6 6 Dispensing Equipment
6A 6A RTV Dispensing 

Equipment - Standard

Automatically dispense RTV to 

/ on part Automatic stand alone system 36,000

6B 6B Fluid Dispensing 

Equipment - Standard Automatically fill engine Automatic stand alone system with remote oil storage. 50

7 7 On-line Test/Gauging

7A 7A

Precision Measuring 

Machine -MiD (eg. Shim 

selection)

Dedicated system to determine 

bearing shims Automatic stand alone system 750,000

7B 7B

Precision Measuring 

Machine - High (e.g. dual 

measuring )

Dedicated system to check 

cover rail to bearing shaft for 

clearances

Automatic stand alone system 1,350,000

7C 7C

Precision Measuring 

Machine - High (e.g. dual 

measuring )

Dedicated system to check 

cover rail to bearing shaft for 

clearances

Semi-automatic stand alone system 1,350,000

7D 7D

Precision Measuring 

Machine - High (e.g. 

Functional Test)

Dedicated system to fill 

transmission and verify 

functions

Automatic stand with remote fluid fill system. 1,265,000

7E 7E

Rotate Measuring 

Machine (e.g. Torque to 

Turn)

Dedicated system to measure 

rotational torques Automatic stand alone system 265,000

7F 7F

Lateral Displacement 

Measuring Machine (e.g. 

Part 

Presence/Orientation)

Dedicated system to measure / 

check part present or part 

orientation.

Automatic stand alone system 73,000

7G 7G Visual (e.g. Part 

Presence/Orientation)

Dedicated visual systen to 

determine part presence / 

orientation.

Automatic stand alone system 47,000

7H 7H Air Test Dedicated sytem to air test, 

plugs or surfaces for leaks Automatic stand alone system 79,000

7J 7J Final oil fill Dedicated system final fill 

transmission Automatic stand alone system 225,000
7K 7K Multiple parts cost Additional cost per part 11,000

8 8 Feeders

8A 8A Single part Automatically feed part to load 

mechanism Automatic stand alone system 36,000

8B 8B Multiple parts Automatically feed part to load 

mechanism Automatic stand alone system 50,000

8C 8C Multiple parts cost Additional cost per part 7,000

9 9 Press stations

9A 9A Single part - High Automatically press single 

bearing or race Automatic stand alone system 189,000

9B 9B Multiple parts cost Automatically press single 

bearing or race Additional cost per part 156,000

9C 9C Single part - Med Semi-automatically press single 

bearing or race Manual load and auto press station 97,000

9D 9D Multiple parts cost Semi-automatically press 

multiple bearing or race Additional cost per part 77,000

9E 9E Multiple part - Low Manually press multiple parts 

(dowels) Manual tooling to press dowels/ plugs 10,000

10 10 Washers & automation

10A 10A Ferris Wheel style Automatic self contained parts 

washer Automatic stand alone system 450,000

10B 10B Final Assebly washer Automatic flow thru parts 

washer Automatic stand alone system with robots 1,100,000
10C 10C Washer pallet automation

Automation to transfer part / 

pallet from rack to washer; 

washer to assembly line

Generic 24" x 24" pallet, (4 per section) 3 feet wide on floor 

transport. Includes pallet stops and controls. 10 overall 

length. Overall floor space to be 5' wide x 10' long - 50 

square feet. Note! 6 sections required - price reflects 6

330,000

11 11 Sub-assembly loop - Low

11A 11A Sub-assembly loop - Low Off-line assembly system (8 

people required)

Automation to assembly main control housing. Low tech with 

simple pallets, manual r/d tools and manual load / unloading 

of parts. No testing required

480,000
$ Square Feet Square Feet

45,000 16 12

45,000 40 12

45,000 24 12

40,000 140 50

140

Pallets @ $30k each. 

Cost is $8k /foot for 

automation with 

controls

Process 

Support 

Equipment 

Costs

Primary 

Equipment Facility 

Floor Space

Process 

Support 

Facility Floor 

Space
0 10

0

0 100

0 150

0 180

0 250

0 250

000

000

0 100

0 160

0 300
0 60 0

132,000 2 800

0 0 0

0 0 0

0 20 0

0 0 0

0 0 0

0 30 0

0 30 0

0 50 0

0 30 0

0 50 0

0 1 0
0 50 0

85,000 10 150

0 50 0

0 150 0

0 150 0

95,000 300 150

0 10 0

0 10 0

0 10 0

0 9 0

50
0 1 0

0 12 0

0 12 0

0 1 0

65,000 4 65

25,000 2 5

65,000 4 65

25,000 2 5

5,000 2 2

100,000 300 120

75,000 400 120
180,000 300 150

121,000 500 400
Transmission Assembly

Volume: 450,000 year

Work pattern Work pattern

48 Weeks 48 Weeks

5 Days 5 Days

7.2 Hours available time per shift 7.2 Hours available time per shift

1 Shift per week 2 Shift per week

36 Hours available per week 72 Hours available per week

1728 Hours available per year 3456 Hours available per year

260 Parts per hour at 100% efficiency 130 Parts per hour at 100% efficiency

302 Parts per hour ar 85% efficiency 151 Parts per hour ar 85% efficiency

12 Cycle time is seconds 24 Cycle time is seconds

0.2 Minutes 0.4 Minutes

System Design Concept

Palletized with simple fixtures designed for heavy parts

Transport will be powered rolers

Electric controls will be simple - colored light for QC control

Overhead pneaumatic lift assits

Structured packaging
0% efficiency