# Sub-Compact **Vehicle Segment**  **Passenger 2-4 Small/Compact** 

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van** 

**Vehicle Segment**  **Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex A**  **Internal Combustion Engine (ICE) System B**  **Integrated Electric Motor/Generator and Clutch Assembly System**  **1,038.80 $**  **1,091.51**

**$ 1,269.82** 

**$ 1,190.83** 

**$** B.1 Case Subsystem 121.22 $ 129.22

$ 156.84

$ 144.79

$ B.2 Launch Clutch Subsystem 84.87 $ 89.40

$ 104.61

$ 98.86

$ B.3 Oil Pump and Filter Subsystem 29.97 $ 31.71

$ 37.61

$ 35.25

$ B.4 Traction Motor - Generator Subsystem 231.95 $ 242.92

$ 278.58

$ 262.12

$ B.5 Passive Power Electronics Component Subsystem (Capacitors, Filters, etc) 78.52 $ 82.86

$ 96.99

$ 90.47

$ B.6 Power Electronics/Inverter & Controls Subsystem 262.03 $ 271.65

$ 302.91

$ 288.49

$ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology **System ID**  **System Description**



# Application**of ICE downsizing credits outside the scope of this analysis**  

# Updated Curb Weight Reductions**& Li -** **Ion Battery: EPA File 041911** 

B.6 Power Electronics/Inverter & Controls Subsystem 262.03 $ 271.65

$ 302.91

$ 288.49

$ B.7 Traction Motor-Generator Sensor Subsystem 38.55 $ 38.55

$ 38.55

$ 38.55

$ B.8 Internal Electrical Connection Subsystem 42.11 $ 42.11

$ 42.11

$ 42.11

$ B.9 Switch Subsystem 3.04 $ 3.04

$ 3.04

$ 3.04

$ B.10 Electrical Housing/Support Structure Subsystem 45.40 $ 53.65

$ 80.48

$ 68.10

$ B.11 Electric Motor/Generator & Clutch Cooling Subsystem 46.76 $ 51.80

$ 72.82

$ 64.09

$ B.12 Other Misc (e.g. brackets, sealing, etc) 3.05 $ 3.26

$ 3.96

$ 3.64

$ B.13 OE Electric Motor/Generator Clutch System Assembly 51.33 $ 51.33

$ 51.33

$ 51.33

$ **C Transmission System** 

- $

-

$

-

$

-

$ **D Body System**  **6.13 $**  **6.25**

**$ 6.30** 

**$ 6.39** 

**$ E**  **Brake System - BBW 225.84**  **$ 230.74** 

**$ 234.42** 

**$ 235.07** 

**$** 

# Assumption:**Carry -** **over Transmission From Baseline Vehicle** 

# F **Steering System - EPS** n/a n/a n/a n/a

**G Climate Control System**  **190.72 $**  **202.51**

**$ 217.77** 

**$ 271.48** 

**$** G.1 >Electric AC Compressor Subsystem 149.56 $ 158.88

$ 170.96

$ 213.45

$ G.2 > Auxiliary Heating Subsystem 41.16 $ 43.62

$ 46.81

$ 58.03

$ **H Electric Power Supply System**  **1,253.72 $**  **1,391.21**

**$ 1,512.44** 

**$ 1,518.78** 

**$** H.1 Service Battery Subsystem (3.47) $ (3.47)

$ (3.47)

$ (3.47)

$ H.2 Generator/Alternator and Regulator Subsystem (56.92) $ (61.23)

$ (78.70)

$ (82.72)

$ **H.3 High Voltage Traction Battery Subsystem (Li**  **Polymer) 1,202.24**  **$ 1,333.93** 

**$ 1,442.29** 

**$ 1,442.54** 

**$** H.3.1 Assembly of Battery 21.70 $ 23.19

$ 24.42

$ 24.42

$ H.3.2 Battery Cells/Modules 643.36 $ 737.42

$ 815.17

$ 815.17

$ H.3.3 Relays/Fuses/Disconnects 163.52 $ 163.52

$ 163.52

$ 163.52

$ H.3.4 Internal Wire Harness Connections 31.27 $ 32.93

$ 34.31

$ 34.31

$ H.3.5 Battery Sensing and Control Modules 250.66 $ 274.82

$ 294.79

$ 294.79

$ H.3.6 Battery Cooling Module 45.18 $ 51.79

$ 57.25

$ 57.25

$ Battery Cooling Module $ $ $ $ H.3.7 Misc Components (e.g. Brackets, Housings, Covers) 14.99 $ 17.18

$ 18.99

$ 18.99

$ H.3.8 Vehicle Interfaces (e.g. Brackets, Wiring, etc) 31.58 $ 33.09

$ 33.84

$ 34.09

$ H.4 Voltage Inverters/Converters Subsystem 111.86 $ 121.98

$ 152.31

$ 162.43

$ **I Power Distribution and Control System**  **197.11 $**  **201.22**

**$ 203.28** 

**$ 203.97** 

**$ Net Incremental Direct Manufacturing Cost**  **2,912.32 $**  **3,123.43**

**$ 3,444.03** 

**$ 3,426.52** 

**$**

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/ Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van** 

**Vehicle Segment**  **Passenger 6-8** 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex** 010000-A Internal Combustion Engine (ICE) System

- $

-

$

-

$

-

$ 010000-B Integrated Electric Motor/Generator and Clutch

Assembly System 1,038.80 $ 1,091.51

$ 1,269.82

$ 1,190.83

$ 020000 Transmission System

- $

-

$

-

$

-

$ 030000 Body System 6.13 $ 6.25

$ 6.30

$ 6.39

$ 060000 Brake System - BBW 225.84 $ 230.74

$ 234.42

$ 235.07

$ 120000 Climate Control System 190.72 $ 202.51

$ 217.77

$ 271.48

$ 140000 Electric Power Supply System 1,253.72 $ 1,391.21

$ 1,512.44

$ 1,518.78

$ 180000 Power Distribution and Control System 197.11 $ 201.22

$ 203.28

$ 203.97

$ Net Incremental Direct Manufacturing Cost 2,912.32 $ 3,123.43

$ 3,444.03

$ 3,426.52

$ Precent Increase In Cost over 20%Net CW Reduction -0.60% -0.72% -3.38% -7.17%

**Sub-Compact Vehicle**  **Segment Small/Compact** 

**Vehicle Segment**  **Large**

**Size/Vehicle Segment**  **Mini Van**

**Vehicle Segment**  

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology Engine technology selection and downsizing outside of analysis scope** 

**Transmission technology selection and downsizing outside of analysis scope**

**Segment Passenger 2-4**  **Segment**

**Passenger 2-5 Segment** 

**Passenger 4-6 Segment** 

**Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex**

010000-B Integrated Electric Motor/Generator and Clutch

Assembly System (Sum of Subsystems B.1 - B.13) 1,038.80 $ 1,091.51

$ 1,269.82

$ 1,190.83

$

B.1 Case Subsystem 121.22 $ 129.22

$ 156.84

$ 144.79

$ B.2 Launch Clutch Subsystem 84.87 $ 89.40

$ 104.61

$ 98.86

$ B.3 Oil Pump and Filter Subsystem 29.97 $ 31.71

$ 37.61

$ 35.25

$ B.4 Traction Motor - Generator Subsystem 231.95 $ 242.92

$ 278.58

$ 262.12

$ B.5 Passive Power Electronics Component Subsystem (Capacitors, Filters, etc) 78.52 $ 82.86

$ 96.99

$ 90.47

$ B.6 Power Electronics/Inverter & Controls Subsystem 262.03 $ 271.65

$ 302.91

$ 288.49

$ B.7 Traction Motor-Generator Sensor Subsystem 38.55 $ 38.55

$ 38.55

$ 38.55

$ 

# ID

# B.8 Internal Electrical Connection Subsystem 42.11 $ 42.11

$ 42.11

$ 42.11

$ B.9 Switch Subsystem 3.04 $ 3.04

$ 3.04

$ 3.04

$ B.10 Electrical Housing/Support Structure Subsystem 45.40 $ 53.65

$ 80.48

$ 68.10

$ B.11 Electric Motor/Generator & Clutch Cooling Subsystem 46.76 $ 51.80

$ 72.82

$ 64.09

$ B.12 Other Misc (e.g. brackets, sealing, etc) 3.05 $ 3.26

$ 3.96

$ 3.64

$ B.13 OE Electric Motor/Generator Clutch System Assembly 51.33 $ 51.33

$ 51.33

$ 51.33

$

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van** 

**Vehicle Segment**  **Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex**

**H Electric Power Supply System**  **1,253.72 $**  **1,391.21**

**$ 1,512.44** 

**$ 1,518.78** 

**$** 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

H.1 Service Battery Subsystem (3.47) $ (3.47)

$ (3.47)

$ (3.47)

$ H.2 Generator/Alternator and Regulator Subsystem (56.92) $ (61.23)

$ (78.70)

$ (82.72)

$

**H.3 High Voltage Traction Battery Subsystem (Li**  **Polymer) 1,202.24**  **$ 1,333.93** 

**$ 1,442.29** 

**$ 1,442.54** 

**$**

H.3.1 Assembly of Battery 21.70 $ 23.19

$ 24.42

$ 24.42

$ H.3.2 Battery Cells/Modules 643.36 $ 737.42

$ 815.17

$ 815.17

$ H.3.3 Relays/Fuses/Disconnects 163.52 $ 163.52

$ 163.52

$ 163.52

$ H.3.4 Internal Wire Harness Connections 31.27 $ 32.93

$ 34.31

$ 34.31

$ H.3.5 Battery Sensing and Control Modules 250.66 $ 274.82

$ 294.79

$ 294.79

$ H.3.6 Battery Cooling Module 45.18 $ 51.79

$ 57.25

$ 57.25

$ H.3.7 Misc Components (e.g. Brackets, Housings, Covers) 14.99 $ 17.18

$ 18.99

$ 18.99

$ H.3.8 Vehicle Interfaces (e.g. Brackets, Wiring, etc) 31.58 $ 33.09

$ 33.84

$ 34.09

$

# H.4 Voltage Inverters/Converters Subsystem 111.86 $ 121.98

$ 152.31

$ 162.43

$

Internal Combustion Engine

(ICE) Transmission ( e.g. AT, ATM, DCT)HighVoltageDistribution 

# Electric Motor/GeneratorFlywheelClutch 

# Clutch & Motor Cooling

Power Electronics/Inverter & Controls Electric Motor/Generator Clutch Assembly

High Voltage Traction Battery 

# P2 System Boundary

Systems Requiring ModificationsHighVoltageDistribution



# Battery Cells/Modules Control Electronics, Sensors, Switches Battery Cooling ModuleRelays,Fuses, 

# High Voltage Traction Battery Body System Brake System Climate Control System 

# Modifications

# Small Truck **Large Truck**

**Ford Ranger Ford Explorer** 

**1,159.44 $**  **1,274.14**

**$** 138.65 $ 161.75

$ 99.30 $ 114.75

$ 33.97 $ 40.44

$ 253.89 $ 273.09

$ 87.21 $ 94.82

$ 281.27 $ 298.11

$ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology



# Application**of ICE downsizing credits outside the scope of this analysis** 



# Ion Battery:**EPA File 041911**

281.27 $ 298.11

$ 38.55 $ 38.55

$ 42.11 $ 42.11

$ 3.04 $ 3.04

$ 61.91 $ 76.35

$ 64.73 $ 75.95

$ 3.47 $ 3.85

$ 51.33 $ 51.33

$

- $

-

$ **6.25 $**  **6.39**

**$ 232.78**  **$ 240.99** 

**$** 

# over Transmission**From Baseline Vehicle**

# n/a n/a

**249.05 $**  **239.85**

**$** 195.71 $ 188.42

$ 53.35 $ 51.42

$ **1,474.39 $**  **1,702.71**

**$** (3.47) $ (3.47)

$ (82.72) $ (90.55)

$ **1,398.15 $**  **1,619.13**

**$** 23.93 $ 26.41

$ 783.82 $ 940.58

$ 163.52 $ 163.52

$ 33.76 $ 36.54

$ 286.74 $ 327.00

$ 55.05 $ 66.06

$ 18.26 $ 21.91

$ 33.09 $ 37.11

$ 162.43 $ 177.59

$ **201.22 $**  **212.20**

**$ 3,323.13**  **$ 3,676.28** 

**$**

**Small Truck Large Truck**  

# Calculated Incremental Manufacturing Cost - P2 HEV Technology **Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/ Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle** 

**Segment Passenger 6-8**  

## Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex** 010000-A Internal Combustion Engine (ICE) System

- $

-

$

-

$ $ 010000-B Integrated Electric Motor/Generator and Clutch 1,038.80 $ 1,091.51

$ 1,269.82

$ 1,190.83

$ 

## System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

**Engine technology selection and downsizing outside of analysis scope**

# Ford Ranger **Ford Explorer**

- $

-

$ 1,159.44 $ 1,274.14

$

- $

-

$ 6.25 $ 6.39

$ 232.78 $ 240.99

$ 249.05 $ 239.85

$ 1,474.39 $ 1,702.71

$ 201.22 $ 212.20

$ 3,323.13 $ 3,676.28

$ -6.61% -6.61%

**Small Truck Large Truck**  

# Calculated Incremental Manufacturing Cost - P2 HEV Technology **Engine technology selection and downsizing outside of analysis scope**

**Transmission technology selection and downsizing outside of analysis scope** 010000-B Integrated Electric Motor/Generator and Clutch Assembly System 1,038.80 $ 1,091.51

$ 1,269.82

$ 1,190.83

$ 020000 Transmission System

- $

-

$

-

$ $ 030000 Body System 6.13 $ 6.25

$ 6.30

$ 6.39

$ 060000 Brake System - BBW 225.84 $ 230.74

$ 234.42

$ 235.07

$ 120000 Climate Control System 190.72 $ 202.51

$ 217.77

$ 271.48

$ 140000 Electric Power Supply System 1,253.72 $ 1,391.21

$ 1,512.44

$ 1,518.78

$ 180000 Power Distribution and Control System 197.11 $ 201.22

$ 203.28

$ 203.97

$ Net Incremental Direct Manufacturing Cost 2,912.32 $ 3,123.43

$ 3,444.03

$ 3,426.52

$ 

## Transmission technology selection and downsizing outside of analysis scope



# Large Truck

**Ford Ranger Ford Explorer**  1,159.44 $ 1,274.14

$

138.65 $ 161.75

$ 99.30 $ 114.75

$ 33.97 $ 40.44

$ 253.89 $ 273.09

$ 87.21 $ 94.82

$ 281.27 $ 298.11

$ 38.55 $ 38.55

$ **Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle** 

**Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  010000-B Integrated Electric Motor/Generator and Clutch

Assembly System (Sum of Subsystems B.1 - B.13) 1,038.80 $ 1,091.51

$ 1,269.82

$ $

B.1 Case Subsystem 121.22 $ 129.22

$ 156.84

$ $ B.2 Launch Clutch Subsystem 84.87 $ 89.40

$ 104.61

$ $ 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

# 42.11 $ 42.11

$ 3.04 $ 3.04

$ 61.91 $ 76.35

$ 64.73 $ 75.95

$ 3.47 $ 3.85

$ 51.33 $ 51.33

$

**Small Truck Large Truck** 

**Ford Ranger Ford Explorer**  **1,474.39 $**  **1,702.71**

**$** 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology B.2 Launch Clutch Subsystem 84.87 $ 89.40

$ 104.61

$ $ B.3 Oil Pump and Filter Subsystem 29.97 $ 31.71

$ 37.61

$ $ B.4 Traction Motor - Generator Subsystem 231.95 $ 242.92

$ 278.58

$ $ B.5 Passive Power Electronics Component Subsystem (Capacitors, Filters, etc) 78.52 $ 82.86

$ 96.99

$ $ B.6 Power Electronics/Inverter & Controls Subsystem 262.03 $ 271.65

$ 302.91

$ $ B.7 Traction Motor-Generator Sensor Subsystem 38.55 $ 38.55

$ 38.55

$ $ B.8 Internal Electrical Connection Subsystem 42.11 $ 42.11

$ 42.11

$ $ B.9 Switch Subsystem 3.04 $ 3.04

$ 3.04

$ $ B.10 Electrical Housing/Support Structure Subsystem 45.40 $ 53.65

$ 80.48

$ $ B.11 Electric Motor/Generator & Clutch Cooling Subsystem 46.76 $ 51.80

$ 72.82

$ $ B.12 Other Misc (e.g. brackets, sealing, etc) 3.05 $ 3.26

$ 3.96

$ $ B.13 OE Electric Motor/Generator Clutch System Assembly 51.33 $ 51.33

$ 51.33

$ $

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle** 

**Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex** 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**



# (3.47) $ (3.47)

$ (82.72) $ (90.55)

$ **1,398.15 $**  **1,619.13**

**$**

23.93 $ 26.41

$ 783.82 $ 940.58

$ 163.52 $ 163.52

$ 33.76 $ 36.54

$ 286.74 $ 327.00

$ 55.05 $ 66.06

$ 18.26 $ 21.91

$ 33.09 $ 37.11

$ **Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle** 

**Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex**

**H Electric Power Supply System**  **1,253.72 $**  **1,391.21**

**$ 1,512.44** 

**$ $** 

H.1 Service Battery Subsystem (3.47) $ (3.47)

$ (3.47)

$ $ H.2 Generator/Alternator and Regulator Subsystem (56.92) $ (61.23)

$ (78.70)

$ $

**H.3 High Voltage Traction Battery Subsystem (Li**  **Polymer) 1,202.24**  **$ 1,333.93** 

**$ 1,442.29** 

**$ $** 

H.3.1 Assembly of Battery 21.70 $ 23.19

$ 24.42

$ $ H.3.2 Battery Cells/Modules 643.36 $ 737.42

$ 815.17

$ $ H.3.3 Relays/Fuses/Disconnects 163.52 $ 163.52

$ 163.52

$ $ H.3.4 Internal Wire Harness Connections 31.27 $ 32.93

$ 34.31

$ $ H.3.5 Battery Sensing and Control Modules 250.66 $ 274.82

$ 294.79

$ $ H.3.6 Battery Cooling Module 45.18 $ 51.79

$ 57.25

$ $ H.3.7 Misc Components (e.g. Brackets, Housings, Covers) 14.99 $ 17.18

$ 18.99

$ $ H.3.8 Vehicle Interfaces (e.g. Brackets, Wiring, etc) 31.58 $ 33.09

$ 33.84

$ $ H.4 Voltage Inverters/Converters Subsystem 111.86 $ 121.98

$ 152.31

$ $ 

# System **ID System Description** 

# 162.43 $ 177.59

$

Transmission ( e.g. AT, ATM, DCT)

High Voltage Traction Battery Internal Combustion Engine (ICE)HighVoltageDistribution 

# Electric Motor/GeneratorFlywheelClutch 

# Clutch & Motor Cooling

Power Electronics/Inverter & Controls Electric Motor/Generator Clutch Assembly

Body System 

# P2 System Boundary

Systems Requiring Modifications

Battery Cells/Modules

Battery Cooling Module High Voltage Traction BatteryHighVoltageDistribution 

# Body System Brake System Climate Control System

# Baseline

**2010 Ford Fusion Power split HEV** 



# Vehicle Example **NA** A **ICE Engine System** $ B **Electric Motor/Generator System** $ C **Transmission System** $ C.1 > 6-Speed AT $ C.2 > 6-Speed DCT $ D **Body System** $ E **Brake System - BBW** $ 

# System **ID System Description** 

D **Body System** $ E **Brake System - BBW** $ F **Steering System - EPS** n/a G **Climate Control System** G.1 >Electric AC Compressor Subsystem $ G.2 > Auxiliary Heating Subsystem $ H **Electric Power Supply (Li-Polymer)** $ H.1 >Battery Modules (High Voltage & Service) $ H.2 >Alternator/Generator Assemblies $ H.3 > Inverters/Converters $ I **Power Distribution and Control System** $ Net Incremental $

### Mini Van Vehicle **Segment Passenger 6-8**  **Small Truck Large Truck** 

**Ford Flex Ford Ranger**  **Ford Explorer**

- $

-

$

-

$ 1,190.83 1,159.44

$ 1,274.14

$ 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**Engine technology selection and downsizing outside of analysis scope**

### 1,190.83 1,159.44

$ 1,274.14

$

- $

-

$

-

$ 6.39 $ 6.25

$ 6.39

$ 235.07 232.78 $ 240.99

$ 271.48 249.05 $ 239.85

$ 1,518.78 1,474.39

$ 1,702.71

$ 203.97 201.22 $ 212.20

$ 3,426.52 3,323.13

$ 3,676.28

$ 

## Transmission technology selection and downsizing outside of analysis scope



## Mini Van Vehicle **Segment Passenger 6-8**  **Small Truck Large Truck** 

**Ford Flex Ford Ranger**  **Ford Explorer** 1,190.83 $ 1,159.44

$ 1,274.14

$

144.79 $ 138.65

$ 161.75

$ 98.86 $ 99.30

$ 114.75

$ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology

## 98.86 $ 99.30

$ 114.75

$ 35.25 $ 33.97

$ 40.44

$ 262.12 $ 253.89

$ 273.09

$ 90.47 $ 87.21

$ 94.82

$ 288.49 $ 281.27

$ 298.11

$ 38.55 $ 38.55

$ 38.55

$ 42.11 $ 42.11

$ 42.11

$ 3.04 $ 3.04

$ 3.04

$ 68.10 $ 61.91

$ 76.35

$ 64.09 $ 64.73

$ 75.95

$ 3.64 $ 3.47

$ 3.85

$ 51.33 $ 51.33

$ 51.33

$

**Mini Van Vehicle Segment**  **Passenger 6-8 Small Truck**  **Large Truck**

**Ford Flex Ford Ranger**  **Ford Explorer** 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology

**Mini Van Vehicle Segment**  **Passenger 6-8 Small Truck**  **Large Truck**

**Ford Flex Ford Ranger**  **Ford Explorer 1,518.78**  **$ 1,474.39** 

**$ 1,702.71** 

**$** (3.47) $ (3.47)

$ (3.47)

$ (82.72) $ (82.72)

$ (90.55)

$ **1,442.54 $**  **1,398.15**

**$ 1,619.13** 

**$**

24.42 $ 23.93

$ 26.41

$ 815.17 $ 783.82

$ 940.58

$ 163.52 $ 163.52

$ 163.52

$ 34.31 $ 33.76

$ 36.54

$ 294.79 $ 286.74

$ 327.00

$ 57.25 $ 55.05

$ 66.06

$ 18.99 $ 18.26

$ 21.91

$ 34.09 $ 33.09

$ 37.11

$ 162.43 $ 162.43

$ 177.59

$

# Transmission ( e.g. AT, ATM, DCT)

High Voltage Traction Battery

Battery Cells/Modules Control Electronics, Sensors, Switches Battery Cooling ModuleRelays,Fuses,Disconnect 

# High Voltage Traction Battery

# Baseline

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Large Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle**  **Segment Passenger 6-8**  **Small Truck**



# NA **Ford Fiesta Ford Focus**  **Ford Fusion Ford Flex**  **Ford Explore (3.5L V6)** 

- $

- $

-

$

-

$

-

$

-

$ $ 1,198.15 $ 998.14 $ 1,044.60

$ 1,164.26

$ 1,114.70

$ 1,140.72

$ $

- $

- $

-

$

-

$

-

$

-

$ $

- $

- $

-

$

-

$

-

$

-

$ $

- $

- $

-

$

-

$

-

$

-

$ $ 7.35 $ 6.96 $ 7.15

$ 7.38

$ 7.58

$ 7.69

$ $ 236.52 $ 218.28 $ 224.19

$ 230.24

$ 235.31

$ 267.13

$ $ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology

7.35 $ 6.96 $ 7.15

$ 7.38

$ 7.58

$ 7.69

$ $ 236.52 $ 218.28 $ 224.19

$ 230.24

$ 235.31

$ 267.13

$ $ n/a n/a n/a n/a n/a n/a

167.83 $ 149.81 $ 159.15

$ 171.25

$ 213.81

$ 196.04

$ $ 45.70 $ 41.16 $ 43.62

$ 46.81

$ 58.03

$ 53.35

$ $

- $

- $

-

$

-

$

-

$

-

$ $ 1,759.15 $ 1,035.30 $ 1,150.39

$ 1,423.48

$ 1,375.18

$ 1,104.95

$ $ (78.70) $ (56.92) $ (61.23)

$ (78.70)

$ (82.72)

$ (82.72)

$ $ 150.91 $ 111.86 $ 121.98

$ 152.31

$ 162.43

$ 162.43

$ $ 201.50 $ 197.11 $ 201.22

$ 203.28

$ 203.97

$ 201.22

$ $ 3,688.42 $ 2,701.70 $ 2,891.07

$ 3,320.32

$ 3,288.29

$ 3,050.80

$ $

# Large Truck

**Ford F150 (6.2L V8)** 

- $

1,252.29 $

- $

- $

- $

7.96 $

318.55 $ n/a

188.75 $ 51.42 $

- $

1,518.12 $ (90.55) $177.59 $212.20 $

3,636.33 $

# Sub-Compact **Vehicle Segment**  **Passenger 2-4 Small/Compact** 

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van** 

**Vehicle Segment**  **Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex A**  **Internal Combustion Engine (ICE) System B**  **Integrated Electric Motor/Generator and Clutch Assembly System**  **1,038.80 $**  **1,091.51**

**$ 1,269.82** 

**$ 1,190.83** 

**$** B.1 Case Subsystem 121.22 $ 129.22

$ 156.84

$ 144.79

$ B.2 Launch Clutch Subsystem 84.87 $ 89.40

$ 104.61

$ 98.86

$ B.3 Oil Pump and Filter Subsystem 29.97 $ 31.71

$ 37.61

$ 35.25

$ B.4 Traction Motor - Generator Subsystem 231.95 $ 242.92

$ 278.58

$ 262.12

$ B.5 Passive Power Electronics Component Subsystem (Capacitors, Filters, etc) 78.52 $ 82.86

$ 96.99

$ 90.47

$ B.6 Power Electronics/Inverter & Controls Subsystem 262.03 $ 271.65

$ 302.91

$ 288.49

$ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology **System ID**  **System Description**



# Application**of ICE downsizing credits outside the scope of this analysis**  

# Updated Curb Weight Reductions**& Li -** **Ion Battery: EPA File 041911** 

B.6 Power Electronics/Inverter & Controls Subsystem 262.03 $ 271.65

$ 302.91

$ 288.49

$ B.7 Traction Motor-Generator Sensor Subsystem 38.55 $ 38.55

$ 38.55

$ 38.55

$ B.8 Internal Electrical Connection Subsystem 42.11 $ 42.11

$ 42.11

$ 42.11

$ B.9 Switch Subsystem 3.04 $ 3.04

$ 3.04

$ 3.04

$ B.10 Electrical Housing/Support Structure Subsystem 45.40 $ 53.65

$ 80.48

$ 68.10

$ B.11 Electric Motor/Generator & Clutch Cooling Subsystem 46.76 $ 51.80

$ 72.82

$ 64.09

$ B.12 Other Misc (e.g. brackets, sealing, etc) 3.05 $ 3.26

$ 3.96

$ 3.64

$ B.13 OE Electric Motor/Generator Clutch System Assembly 51.33 $ 51.33

$ 51.33

$ 51.33

$ **C Transmission System** 

- $

-

$

-

$

-

$ **D Body System**  **6.13 $**  **6.25**

**$ 6.30** 

**$ 6.39** 

**$ E**  **Brake System - BBW 225.84**  **$ 230.74** 

**$ 234.42** 

**$ 235.07** 

**$** 

# Assumption:**Carry -** **over Transmission From Baseline Vehicle** 

# F **Steering System - EPS** n/a n/a n/a n/a

**G Climate Control System**  **190.72 $**  **202.51**

**$ 217.77** 

**$ 271.48** 

**$** G.1 >Electric AC Compressor Subsystem 149.56 $ 158.88

$ 170.96

$ 213.45

$ G.2 > Auxiliary Heating Subsystem 41.16 $ 43.62

$ 46.81

$ 58.03

$ **H Electric Power Supply System**  **1,253.72 $**  **1,391.21**

**$ 1,512.44** 

**$ 1,518.78** 

**$** H.1 Service Battery Subsystem (3.47) $ (3.47)

$ (3.47)

$ (3.47)

$ H.2 Generator/Alternator and Regulator Subsystem (56.92) $ (61.23)

$ (78.70)

$ (82.72)

$ **H.3 High Voltage Traction Battery Subsystem (Li**  **Polymer) 1,202.24**  **$ 1,333.93** 

**$ 1,442.29** 

**$ 1,442.54** 

**$** H.3.1 Assembly of Battery 21.70 $ 23.19

$ 24.42

$ 24.42

$ H.3.2 Battery Cells/Modules 643.36 $ 737.42

$ 815.17

$ 815.17

$ H.3.3 Relays/Fuses/Disconnects 163.52 $ 163.52

$ 163.52

$ 163.52

$ H.3.4 Internal Wire Harness Connections 31.27 $ 32.93

$ 34.31

$ 34.31

$ H.3.5 Battery Sensing and Control Modules 250.66 $ 274.82

$ 294.79

$ 294.79

$ H.3.6 Battery Cooling Module 45.18 $ 51.79

$ 57.25

$ 57.25

$ Battery Cooling Module $ $ $ $ H.3.7 Misc Components (e.g. Brackets, Housings, Covers) 14.99 $ 17.18

$ 18.99

$ 18.99

$ H.3.8 Vehicle Interfaces (e.g. Brackets, Wiring, etc) 31.58 $ 33.09

$ 33.84

$ 34.09

$ H.4 Voltage Inverters/Converters Subsystem 111.86 $ 121.98

$ 152.31

$ 162.43

$ **I Power Distribution and Control System**  **197.11 $**  **201.22**

**$ 203.28** 

**$ 203.97** 

**$ Net Incremental Direct Manufacturing Cost**  **2,912.32 $**  **3,123.43**

**$ 3,444.03** 

**$ 3,426.52** 

**$**

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/ Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van** 

**Vehicle Segment**  **Passenger 6-8** 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex** 010000-A Internal Combustion Engine (ICE) System

- $

-

$

-

$

-

$ 010000-B Integrated Electric Motor/Generator and Clutch

Assembly System 1,038.80 $ 1,091.51

$ 1,269.82

$ 1,190.83

$ 020000 Transmission System

- $

-

$

-

$

-

$ 030000 Body System 6.13 $ 6.25

$ 6.30

$ 6.39

$ 060000 Brake System - BBW 225.84 $ 230.74

$ 234.42

$ 235.07

$ 120000 Climate Control System 190.72 $ 202.51

$ 217.77

$ 271.48

$ 140000 Electric Power Supply System 1,253.72 $ 1,391.21

$ 1,512.44

$ 1,518.78

$ 180000 Power Distribution and Control System 197.11 $ 201.22

$ 203.28

$ 203.97

$ Net Incremental Direct Manufacturing Cost 2,912.32 $ 3,123.43

$ 3,444.03

$ 3,426.52

$ Precent Increase In Cost over 20%Net CW Reduction -0.60% -0.72% -3.38% -7.17%

**Sub-Compact Vehicle**  **Segment Small/Compact** 

**Vehicle Segment**  **Large**

**Size/Vehicle Segment**  **Mini Van**

**Vehicle Segment**  

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology Engine technology selection and downsizing outside of analysis scope** 

**Transmission technology selection and downsizing outside of analysis scope**

**Segment Passenger 2-4**  **Segment**

**Passenger 2-5 Segment** 

**Passenger 4-6 Segment** 

**Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex**

010000-B Integrated Electric Motor/Generator and Clutch

Assembly System (Sum of Subsystems B.1 - B.13) 1,038.80 $ 1,091.51

$ 1,269.82

$ 1,190.83

$

B.1 Case Subsystem 121.22 $ 129.22

$ 156.84

$ 144.79

$ B.2 Launch Clutch Subsystem 84.87 $ 89.40

$ 104.61

$ 98.86

$ B.3 Oil Pump and Filter Subsystem 29.97 $ 31.71

$ 37.61

$ 35.25

$ B.4 Traction Motor - Generator Subsystem 231.95 $ 242.92

$ 278.58

$ 262.12

$ B.5 Passive Power Electronics Component Subsystem (Capacitors, Filters, etc) 78.52 $ 82.86

$ 96.99

$ 90.47

$ B.6 Power Electronics/Inverter & Controls Subsystem 262.03 $ 271.65

$ 302.91

$ 288.49

$ B.7 Traction Motor-Generator Sensor Subsystem 38.55 $ 38.55

$ 38.55

$ 38.55

$ 

# ID

# B.8 Internal Electrical Connection Subsystem 42.11 $ 42.11

$ 42.11

$ 42.11

$ B.9 Switch Subsystem 3.04 $ 3.04

$ 3.04

$ 3.04

$ B.10 Electrical Housing/Support Structure Subsystem 45.40 $ 53.65

$ 80.48

$ 68.10

$ B.11 Electric Motor/Generator & Clutch Cooling Subsystem 46.76 $ 51.80

$ 72.82

$ 64.09

$ B.12 Other Misc (e.g. brackets, sealing, etc) 3.05 $ 3.26

$ 3.96

$ 3.64

$ B.13 OE Electric Motor/Generator Clutch System Assembly 51.33 $ 51.33

$ 51.33

$ 51.33

$

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5 Large** 

**Size/Vehicle Segment**  **Passenger 4-6 Mini Van** 

**Vehicle Segment**  **Passenger 6-8** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and Taurus**  **Ford Flex**

**H Electric Power Supply System**  **1,253.72 $**  **1,391.21**

**$ 1,512.44** 

**$ 1,518.78** 

**$** 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

H.1 Service Battery Subsystem (3.47) $ (3.47)

$ (3.47)

$ (3.47)

$ H.2 Generator/Alternator and Regulator Subsystem (56.92) $ (61.23)

$ (78.70)

$ (82.72)

$

**H.3 High Voltage Traction Battery Subsystem (Li**  **Polymer) 1,202.24**  **$ 1,333.93** 

**$ 1,442.29** 

**$ 1,442.54** 

**$**

H.3.1 Assembly of Battery 21.70 $ 23.19

$ 24.42

$ 24.42

$ H.3.2 Battery Cells/Modules 643.36 $ 737.42

$ 815.17

$ 815.17

$ H.3.3 Relays/Fuses/Disconnects 163.52 $ 163.52

$ 163.52

$ 163.52

$ H.3.4 Internal Wire Harness Connections 31.27 $ 32.93

$ 34.31

$ 34.31

$ H.3.5 Battery Sensing and Control Modules 250.66 $ 274.82

$ 294.79

$ 294.79

$ H.3.6 Battery Cooling Module 45.18 $ 51.79

$ 57.25

$ 57.25

$ H.3.7 Misc Components (e.g. Brackets, Housings, Covers) 14.99 $ 17.18

$ 18.99

$ 18.99

$ H.3.8 Vehicle Interfaces (e.g. Brackets, Wiring, etc) 31.58 $ 33.09

$ 33.84

$ 34.09

$

# H.4 Voltage Inverters/Converters Subsystem 111.86 $ 121.98

$ 152.31

$ 162.43

$

Internal Combustion Engine

(ICE) Transmission ( e.g. AT, ATM, DCT)HighVoltageDistribution 

# Electric Motor/GeneratorFlywheelClutch 

# Clutch & Motor Cooling

Power Electronics/Inverter & Controls Electric Motor/Generator Clutch Assembly

High Voltage Traction Battery 

# P2 System Boundary

Systems Requiring ModificationsHighVoltageDistribution



# Battery Cells/Modules Control Electronics, Sensors, Switches Battery Cooling ModuleRelays,Fuses, 

# High Voltage Traction Battery Body System Brake System Climate Control System 

# Modifications

# Small Truck **Large Truck**

**Ford Ranger Ford Explorer** 

**1,159.44 $**  **1,274.14**

**$** 138.65 $ 161.75

$ 99.30 $ 114.75

$ 33.97 $ 40.44

$ 253.89 $ 273.09

$ 87.21 $ 94.82

$ 281.27 $ 298.11

$ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology



# Application**of ICE downsizing credits outside the scope of this analysis** 



# Ion Battery:**EPA File 041911**

281.27 $ 298.11

$ 38.55 $ 38.55

$ 42.11 $ 42.11

$ 3.04 $ 3.04

$ 61.91 $ 76.35

$ 64.73 $ 75.95

$ 3.47 $ 3.85

$ 51.33 $ 51.33

$

- $

-

$ **6.25 $**  **6.39**

**$ 232.78**  **$ 240.99** 

**$** 

# over Transmission**From Baseline Vehicle**

# n/a n/a

**249.05 $**  **239.85**

**$** 195.71 $ 188.42

$ 53.35 $ 51.42

$ **1,474.39 $**  **1,702.71**

**$** (3.47) $ (3.47)

$ (82.72) $ (90.55)

$ **1,398.15 $**  **1,619.13**

**$** 23.93 $ 26.41

$ 783.82 $ 940.58

$ 163.52 $ 163.52

$ 33.76 $ 36.54

$ 286.74 $ 327.00

$ 55.05 $ 66.06

$ 18.26 $ 21.91

$ 33.09 $ 37.11

$ 162.43 $ 177.59

$ **201.22 $**  **212.20**

**$ 3,323.13**  **$ 3,676.28** 

**$**

**Small Truck Large Truck**  

# Calculated Incremental Manufacturing Cost - P2 HEV Technology

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/ Compact**

**Vehicle Segment**  **Passenger 2-5** 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology** 

# 20% Curb Weight Reduction Across**All Vehicle Segments**

# Ford Ranger **Ford Explorer**

- $

-

$ 1,159.44 $ 1,274.14

$

- $

-

$ 6.25 $ 6.39

$ 232.78 $ 240.99

$ 249.05 $ 239.85

$ 1,474.39 $ 1,702.71

$ 201.22 $ 212.20

$ 3,323.13 $ 3,676.28

$ -6.61% -6.61%

**Small Truck Large Truck**  

# Calculated Incremental Manufacturing Cost - P2 HEV Technology **Engine technology selection and downsizing outside of analysis scope**

**Transmission technology selection and downsizing outside of analysis scope** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and**

010000-A Internal Combustion Engine (ICE) System

- $

-

$ 010000-B Integrated Electric Motor/Generator and Clutch

Assembly System 986.22 $ 1,031.39

$ $ 020000 Transmission System

- $

-

$ 030000 Body System 7.07 $ 7.27

$ $ 060000 Brake System - BBW 219.65 $ 224.15

$ $ 120000 Climate Control System 190.98 $ 202.78

$ $ 140000 Electric Power Supply System 1,328.76 $ 1,479.18

$ $ 180000 Power Distribution and Control System 197.11 $ 201.22

$ $ Net Incremental Direct Manufacturing Cost 2,929.78 $ 3,145.99

$ $ 

# Engine technology selection and downsizing outside of analysis scope

**Transmission technology selection and downsizing outside of analysis scope**

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5** 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

**Large Truck**

**Ford Ranger Ford Explorer**  1,159.44 $ 1,274.14

$

138.65 $ 161.75

$ 99.30 $ 114.75

$ 33.97 $ 40.44

$ 253.89 $ 273.09

$ 87.21 $ 94.82

$ 281.27 $ 298.11

$ 38.55 $ 38.55

$ **Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and**

010000-B Integrated Electric Motor/Generator and Clutch

Assembly System (Sum of Subsystems B.1 - B.13) 986.22 $ 1,031.39

$ $

B.1 Case Subsystem 113.84 $ 120.65

$ $ B.2 Launch Clutch Subsystem 79.54 $ 85.13

$ $ B.3 Oil Pump and Filter Subsystem 28.16 $ 29.84

$ $ B.4 Traction Motor - Generator Subsystem 223.72 $ 231.95

$ $ B.5 Passive Power Electronics Component Subsystem (Capacitors, Filters, etc) 74.91 $ 78.35

$ $ B.6 Power Electronics/Inverter & Controls Subsystem 254.05 $ 261.67

$ $ B.7 Traction Motor-Generator Sensor Subsystem 38.55 $ 38.55

$ $ 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology**

# 42.11 $ 42.11

$ 3.04 $ 3.04

$ 61.91 $ 76.35

$ 64.73 $ 75.95

$ 3.47 $ 3.85

$ 51.33 $ 51.33

$

**Small Truck Large Truck** 

**Ford Ranger Ford Explorer**  **1,474.39 $**  **1,702.71**

**$** 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology

**Sub-Compact Vehicle**  **Segment Passenger 2-4**  **Small/Compact**

**Vehicle Segment**  **Passenger 2-5** 

# Vehicle Example **Ford Fiesta Ford Focus**  **Ford Fusion and**

H Electric Power Supply System (SumofSubsystems H.1 - H.4) 1,328.76 $ 1,479.18

$ $

H.1 Service Battery Subsystem (3.47) $ (3.47)

$ 

# System **ID System Description**  **Calculated Incremental Manufacturing Cost - P2 HEV Technology** B.8 Internal Electrical Connection Subsystem 42.11 $ 42.11

$ $ B.9 Switch Subsystem 2.95 $ 2.95

$ $ B.10 Electrical Housing/Support Structure Subsystem 38.54 $ 45.09

$ $ B.11 Electric Motor/Generator & Clutch Cooling Subsystem 35.65 $ 40.73

$ $ B.12 Other Misc (e.g. brackets, sealing, etc) 2.86 $ 3.03

$ $ B.13 OE Electric Motor/Generator Clutch System Assembly 51.33 $ 51.33

$ $



# (3.47) $ (3.47)

$ (82.72) $ (90.55)

$ **1,398.15 $**  **1,619.13**

**$**

23.93 $ 26.41

$ 783.82 $ 940.58

$ 163.52 $ 163.52

$ 33.76 $ 36.54

$ 286.74 $ 327.00

$ 55.05 $ 66.06

$ 18.26 $ 21.91

$ 33.09 $ 37.11

$ H Electric Power Supply System (SumofSubsystems H.1 - H.4) 1,328.76 $ 1,479.18

$ $

H.1 Service Battery Subsystem (3.47) $ (3.47)

$ H.2 Generator/Alternator and Regulator Subsystem (56.92) $ (61.23)

$

H.3 High Voltage Traction Battery Subsystem (Li-Polymer) (Sum of Components H.3.1 - H.3.8) 1,277.28 $ 1,421.90

$ $ H.3.1 Assembly of Battery 19.95 $ 21.20

$ $ H.3.2 Battery Cells/Modules 760.77 $ 873.55

$ $ H3.3 Relays/Fuses/Disconnects 163.52 $ 163.52

$ $ H3.4 Internal Wire Harness Connections 29.31 $ 30.71

$ $ H3.5 Battery Sensing and Control Modules 222.31 $ 242.60

$ $ H3.6 Battery Cooling Module 37.43 $ 42.98

$ $ H3.7 Misc Components (e.g. Brackets, Housings, Covers) 12.42 $ 14.26

$ $ H 3.8 Vehicle Interfaces (e.g. Brackets, Wiring, etc) 31.58 $ 33.09

$ $

# 162.43 $ 177.59

$ etc) H.4 Voltage Inverters/Converters Subsystem 111.86 $ 121.98

$ $



# Transmission ( e.g. AT, ATM, DCT)

High Voltage Traction Battery Internal Combustion Engine (ICE)HighVoltageDistribution 

# Electric Motor/GeneratorFlywheelClutch 

# Clutch & Motor Cooling

Power Electronics/Inverter & Controls Electric Motor/Generator Clutch Assembly

Body System 

# P2 System Boundary

Systems Requiring Modifications

Battery Cells/Modules

Battery Cooling Module High Voltage Traction BatteryHighVoltageDistribution 

# Body System Brake System Climate Control System

# Baseline

**2010 Ford Fusion Power split HEV** 



# Vehicle Example **NA** A **ICE Engine System** $ B **Electric Motor/Generator System** $ C **Transmission System** $ C.1 > 6-Speed AT $ C.2 > 6-Speed DCT $ D **Body System** $ E **Brake System - BBW** $ 

# System **ID System Description** 

D **Body System** $ E **Brake System - BBW** $ F **Steering System - EPS** n/a G **Climate Control System** G.1 >Electric AC Compressor Subsystem $ G.2 > Auxiliary Heating Subsystem $ H **Electric Power Supply (Li-Polymer)** $ H.1 >Battery Modules (High Voltage & Service) $ H.2 >Alternator/Generator Assemblies $ H.3 > Inverters/Converters $ I **Power Distribution and Control System** $ Net Incremental $

# Large **Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle** 

**Segment Passenger 6-8**  **Small Truck Large Truck**  

# Calculated Incremental Manufacturing Cost - P2 HEV Technology 

# 20% Curb Weight Reduction Across**All Vehicle Segments**

# Ford Fusion and **Taurus Ford Flex**  **Ford Ranger Ford Explorer** 

- $

-

$

-

$

-

$ 1,215.56 $ 1,168.73

$ 1,144.30

$ 1,247.18

$

- $

-

$

-

$

-

$ 7.37 $ 7.49

$ 7.27

$ 7.65

$ 229.96 $ 233.04

$ 230.86

$ 238.17

$ 218.06 $ 271.84

$ 249.39

$ 240.17

$ 1,690.43 $ 1,806.21

$ 1,725.30

$ 1,991.08

$ 203.28 $ 203.97

$ 201.22

$ 212.20

$ 3,564.66 $ 3,691.28

$ 3,558.34

$ 3,936.46

$ 

# Engine technology selection and downsizing outside of analysis scope

**Transmission technology selection and downsizing outside of analysis scope**

**Large Size/Vehicle**  **Segment Passenger 4-6**  **Mini Van Vehicle**

**Segment Passenger 6-8**  **Small Truck Large Truck**  

# Calculated Incremental Manufacturing Cost - P2 HEV Technology **Large Size/Vehicle**  **Segment Passenger 4-6**  **Mini Van Vehicle**

**Segment Passenger 6-8**  **Small Truck Large Truck** 

**Ford Fusion and Taurus**  **Ford Flex Ford Ranger**  **Ford Explorer** 1,215.56 $ 1,168.73

$ 1,144.30

$ 1,247.18

$

148.87 $ 141.20

$ 135.18

$ 156.29

$ 100.16 $ 101.73

$ 108.26

$ 120.16

$ 35.57 $ 34.41

$ 32.88

$ 39.29

$ 267.61 $ 256.63

$ 248.41

$ 264.86

$ 93.08 $ 88.63

$ 85.56

$ 92.49

$ 294.26 $ 284.42

$ 277.62

$ 292.96

$ 38.55 $ 38.55

$ 38.55

$ 38.55

$ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology

# Large **Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle** 

**Segment Passenger 6-8**  **Small Truck Large Truck** 

**Ford Fusion and Taurus**  **Ford Flex Ford Ranger**  **Ford Explorer** 1,690.43 $ 1,806.21

$ 1,725.30

$ 1,991.08

$ (3.47) $ (3.47)

$ (3.47)

$ (3.47)

$ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology 42.11 $ 42.11

$ 42.11

$ 42.11

$ 2.95 $ 2.95

$ 2.95

$ 2.95

$ 73.05 $ 64.61

$ 58.77

$ 71.94

$ 64.29 $ 58.63

$ 59.32

$ 70.54

$ 3.74 $ 3.52

$ 3.38

$ 3.71

$ 51.33 $ 51.33

$ 51.33

$ 51.33

$

**Taurus** 1,690.43 $ 1,806.21

$ 1,725.30

$ 1,991.08

$ (3.47) $ (3.47)

$ (3.47)

$ (3.47)

$ (78.70) $ (82.72)

$ (82.72)

$ (90.55)

$ 1,620.29 $ 1,729.97

$ 1,649.06

$ 1,907.51

$

22.93 $ 19.78

$ 23.19

$ 25.42

$ 1,029.28 $ 1,118.79

$ 1,052.55

$ 1,253.04

$ 163.52 $ 163.52

$ 163.52

$ 163.52

$ 32.64 $ 33.76

$ 32.93

$ 35.42

$ 270.63 $ 286.74

$ 274.82

$ 310.90

$ 50.64 $ 55.05

$ 51.79

$ 61.65

$ 16.80 $ 18.26

$ 17.18

$ 20.45

$ 33.84 $ 34.09

$ 33.09

$ 37.11

$

# 152.31 $ 162.43

$ 162.43

$ 177.59

$



# Transmission ( e.g. AT, ATM, DCT)

High Voltage Traction Battery

Battery Cells/Modules Control Electronics, Sensors, Switches Battery Cooling ModuleRelays,Fuses,Disconnect 

# High Voltage Traction Battery

# Baseline

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Large Size/Vehicle Segment**  **Passenger 4-6 Mini Van Vehicle**  **Segment Passenger 6-8**  **Small Truck**



# NA **Ford Fiesta Ford Focus**  **Ford Fusion Ford Flex**  **Ford Explore (3.5L V6)** 

- $

- $

-

$

-

$

-

$

-

$ $ 1,198.15 $ 998.14 $ 1,044.60

$ 1,164.26

$ 1,114.70

$ 1,140.72

$ $

- $

- $

-

$

-

$

-

$

-

$ $

- $

- $

-

$

-

$

-

$

-

$ $

- $

- $

-

$

-

$

-

$

-

$ $ 7.35 $ 6.96 $ 7.15

$ 7.38

$ 7.58

$ 7.69

$ $ 236.52 $ 218.28 $ 224.19

$ 230.24

$ 235.31

$ 267.13

$ $ 

# Calculated Incremental Manufacturing Cost - P2 HEV Technology

7.35 $ 6.96 $ 7.15

$ 7.38

$ 7.58

$ 7.69

$ $ 236.52 $ 218.28 $ 224.19

$ 230.24

$ 235.31

$ 267.13

$ $ n/a n/a n/a n/a n/a n/a

167.83 $ 149.81 $ 159.15

$ 171.25

$ 213.81

$ 196.04

$ $ 45.70 $ 41.16 $ 43.62

$ 46.81

$ 58.03

$ 53.35

$ $

- $

- $

-

$

-

$

-

$

-

$ $ 1,759.15 $ 1,035.30 $ 1,150.39

$ 1,423.48

$ 1,375.18

$ 1,104.95

$ $ (78.70) $ (56.92) $ (61.23)

$ (78.70)

$ (82.72)

$ (82.72)

$ $ 150.91 $ 111.86 $ 121.98

$ 152.31

$ 162.43

$ 162.43

$ $ 201.50 $ 197.11 $ 201.22

$ 203.28

$ 203.97

$ 201.22

$ $ 3,688.42 $ 2,701.70 $ 2,891.07

$ 3,320.32

$ 3,288.29

$ 3,050.80

$ $

# Large Truck

**Ford F150 (6.2L V8)** 

- $

1,252.29 $

- $

- $

- $

7.96 $

318.55 $ n/a

188.75 $ 51.42 $

- $

1,518.12 $ (90.55) $177.59 $212.20 $

3,636.33 $

### Page:1 of 6 

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

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

# 010101 Engine Sy**stem**

1 **00 Engine System Top Level**  **506.26 $**  **145.72**

**$ 518.82** 

**$ 1,170.80** 

**$ 17.66** 

**$ 55.10** 

**$ 54.28** 

**$ 19.29** 

**$ 146.33** 

**$ 3.80** 

**$ 1,320.94** 

**$ -** 

**$ -** 

**$ -** 

**$ 715.90** 

**$ 206.07** 

**$ 733.66** 

**$** 

### 2 **02 Engine Frames, Mounting and Brackets Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 3 **03 Crank Drive Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 4 **04 Counter Balance Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **05 Cylinder Block Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ Net**  **Component/ Assembly**  **Cost Impact to OEM**  **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### Subsystem Description **Investment (X1000)**  

# 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 Manufacturing 

# Technology**Level:** Power

-Split HEV Technology **Vehicle Class:**Mid to Large Size Passenger Vehicle, 4

-6 Passengers 

# Study Case#:0502(N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **06 Cylinder Head Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 7 **07 Valvetrain Subsystem**  **- $**  **-**

**$ -** 

**$ `**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 8 **08 Timing Drive Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 9 **09 Accessory Drive Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 10 **10 Intake Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 11 **11 Fuel Induction Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 12 **12 Exhaust Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 13 **13 Lubrication Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 14 **14 Cooling Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 15 **15 Induction Air Charging Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 16 **16 Exhaust Gas Re-Circulation Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 17 **17 Breather Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 18 **60 Engine Management, Engine Electronic, Electrical Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 19 **70 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 6 

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

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### Subsystem Description **Investment (X1000)**  

# 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 Manufacturing 

# 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)

20 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 0 **NA 506.26**  **$ 145.72** 

**$ 518.82** 

**$ 1,170.80** 

**$ 17.66** 

**$ 55.10** 

**$ 54.28** 

**$ 19.29** 

**$ 146.33** 

**$ 3.80** 

**$ 1,320.94** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 715.90

**$ 206.07** 

**$ 733.66** 

**$**

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

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



# 010101 Engine Sy**stem**

1 **00** 2 **02** 3 **03** 4 **04** 5 **05**ItemSubsystem 

# 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

**1,655.63 $**  **24.98**

**$ 77.91** 

**$ 76.76** 

**$ 27.28** 

**$ 206.93** 

**$ 5.38** 

**$ 1,867.94** 

**$ -** 

**$ -** 

**$ -** 

**$ (209.64)** 

**$ (60.35)** 

**$ (214.84)** 

**$ (484.83)** 

**$ (7.32)** 

**$ (22.81)** 

**$ (22.48)** 

**$ (7.99)** 

**$ (60.60)** 

**$ (1.58)** 

**$ (547.00)** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$**

**- $**  **-**

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**$ -** 

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**$**

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**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000) Total**  **Manufacturing Cost**  **(Component/ Assembly)**  Markup 

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

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

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

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



### 6 **06** 7 **07** 8 **08** 9 **09** 10 **10** 11 **11** 12 **12** 13 **13** 14 **14** 15 **15** 16 **16** 17 **17**

18 **60 -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 19 **70 -** 

**$ -** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0**

**0** End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000) Total**  **Manufacturing Cost**  **(Component/ Assembly)**  Markup 

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

**- $**  **-**

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**$** 

### 1,655.63 **$ 24.98** 

**$ 77.91** 

**$ 76.76** 

**$ 27.28** 

**$ 206.93** 

**$ 5.38** 

**$ 1,867.94** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### (209.64)

**$ (60.35)** 

**$ (214.84)** 

**$ (484.83)** 

**$ (7.32)** 

**$ (22.81)** 

**$ (22.48)** 

**$ (7.99)** 

**$ (60.60)** 

**$ (1.58)** 

**$ (547.00)** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

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



# 010101 Engine Sy**stem**

1 **00** 2 **02** 3 **03** 4 **04** 5 **05**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$ Tooling**  **(x1000) Investment(X1** 

**000)**



### 6 **06** 7 **07** 8 **08** 9 **09** 10 **10** 11 **11** 12 **12** 13 **13** 14 **14** 15 **15** 16 **16** 17 **17**

18 **60 -** 

**$ -** 

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**



### 19 **70 -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0**

**0 Tooling**  **(x1000) Investment(X1** 

**000)**

**- $**  **-**

**$**

**- $**  **-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 2 

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

**Ford Fiesta Ford Focus**  **Ford Fusion Ford Flex**  **Ford Explore (3.5L V6)**  **Ford F150 (6.2L V8)**  

# 010000A **Integrated Motor/Generator A ssembly** 

1 **01 External Component Subsystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 2 **02 Case Subsystem**  **121.22 $**  **129.22 $**  **156.84 $**  **144.79 $**  **138.65 $**  **161.75 $**  

### 3 **03 Gear Train Subystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 4 **04 Internal Clutch Subsystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 5 **05 Launch Clutch Subsystem**  **84.87 $**  **89.40 $**  **104.61 $**  **98.86 $**  **99.30 $**  **114.75 $** Subsystem 

### Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItem 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology
**Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

6 **06 Oil Pump and Filter Subsystem**  **29.97 $**  **31.71 $**  **37.61 $**  **35.25 $**  **33.97 $**  **40.44 $**  

### 7 **07 Mechanical Controls Subsystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 8 **08A Electrical Controls Subsystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 9 **08B Transmission Control Module (Est. $150)**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 10 **09 Parking Mechanism Subsystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 11 **10 Misc Subsystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  

### 12 **11 Electric Motor & Controls Subsystem**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **-1101-Traction and Generator Motors 231.95**  **$ 242.92**  **$ 278.58**  **$ 262.12**  **$ 253.89**  **$ 273.09**  **$ -1102- Power Electronic Components and Assemblies**  **78.52 $**  **82.86 $**  **96.99 $**  **90.47 $**  **87.21 $**  **94.82 $**  **-1103- Control Modules 262.03**  **$ 271.65**  **$ 302.91**  **$ 288.49**  **$ 281.27**  **$ 298.11**  **$ -1104- Traction and Generator Motor Sensors**  **38.55 $**  **38.55 $**  **38.55 $**  **38.55 $**  **38.55 $**  **38.55 $**  **-1105- Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  **42.11 $**  **42.11 $**  **42.11 $**  **42.11 $**  **42.11 $**  **42.11 $** 

**-1115- Switches 3.04**  **$ 3.04**  **$ 3.04**  **$ 3.04**  **$ 3.04**  **$ 3.04**  **$ -1172- Electrical Housings/Support Structure**  **45.40 $**  **53.65 $**  **80.48 $**  **68.10 $**  **61.91 $**  **76.35 $** 



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 2 

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

**Ford Fiesta Ford Focus**  **Ford Fusion Ford Flex**  **Ford Explore (3.5L V6)**  **Ford F150 (6.2L V8)** Subsystem 

### Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItem 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology
**Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**-1175- Brackets 2.03**  **$ 2.03**  **$ 2.03**  **$ 2.03**  **$ 2.03**  **$ 2.03**  **$** Most Associated w. internal wire harness **-1185- Sealing Elements 1.02**  **$ 1.23**  **$ 1.92**  **$ 1.60**  **$ 1.44**  **$ 1.82**  **$** Gasket for cover est @ 2/3 based on electronic housing and cover starting point 

### 13 **12 Transmission Cooling System**  **46.76 $**  **51.80 $**  **72.82 $**  **64.09 $**  **64.73 $**  **75.95 $** 



### 14 **13 OE Transmission Assembly (brokeout for eCVT only, included in** 

**subsystem roll-ups in base analysis) 51.33**  **$ 51.33**  **$ 51.33**  **$ 51.33**  **$ 51.33**  **$ 51.33**  **$** Assume Assembly Cost Would be Approx 50% and constant based on size



### 15 **1,038.80 $**  **1,091.51 $**  **1,269.82 $**  **1,190.83 $**  **1,159.44 $**  **1,274.14 $**  **SYSTEM ROLL-UP**

16 17 18 19 20

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 4 

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



## Baseline

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

## NA **Ford Fiesta Ford Focus**  

# 010000A **Integrated Motor/Generator A ssembly** 

1 **01 External Component Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 2 **02 Case Subsystem**  **85.05 $**  **16.43**

**$ 81.14** 

**$ 182.62** 

**$ 4.90** 

**$ 7.97** 

**$ 8.82** 

**$ 2.10** 

**$ 23.79** 

**$ 1.97** 

**$ 208.39** 

**$ 121.22**  **$ 129.22**  **$** 

### 3 **03 Gear Train Subystem**  **74.98 $**  **21.74**

**$ 37.08** 

**$ 133.80** 

**$ 1.31** 

**$ 14.84** 

**$ 13.45** 

**$ 4.13** 

**$ 33.74** 

**$ 0.41** 

**$ 167.95** 

**$ -**  **$ -**  **$** 

### 4 **04 Internal Clutch Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 5 **05 Launch Clutch Subsystem**  **20.93 $**  **11.40**

**$ 15.35** 

**$ 47.67** 

**$ 0.51** 

**$ 1.96** 

**$ 1.81** 

**$ 0.30** 

**$ 4.59** 

**$ 0.24** 

**$ 52.51** 

**$ 84.87**  **$ 89.40**  **$ Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5** Subsystem 

### Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItem 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

# Technology**Level:** Power

-Split HEV Technology **Vehicle Class:**Mid to Large Size Passenger Vehicle, 4

-6 Passengers 

# Study Case#:0502(N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **06 Oil Pump and Filter Subsystem**  **2.52 $**  **1.77**

**$ 3.68** 

**$ 7.97** 

**$ 0.33** 

**$ 0.54** 

**$ 0.50** 

**$ 0.21** 

**$ 1.56** 

**$ 0.05** 

**$ 9.58** 

**$ 29.97**  **$ 31.71**  **$** 

### 7 **07 Mechanical Controls Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 8 **08A Electrical Controls Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 9 **08B Transmission Control Module (Est. $150)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 10 **09 Parking Mechanism Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 11 **10 Misc Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 12 **11 Electric Motor & Controls Subsystem**  **793.95 $**  **208.98**

**$ 337.24** 

**$ 1,340.17** 

**$ 10.01** 

**$ 96.40** 

**$ 103.22** 

**$ 49.50** 

**$ 259.12** 

**$ 3.25** 

**$ 1,602.54** 

**$ -**  **$ -**  **$** 

### 13 **12 Transmission Cooling System**  **32.91 $**  **13.04**

**$ 13.89** 

**$ 59.84** 

**$ 0.40** 

**$ 5.85** 

**$ 4.93** 

**$ 1.55** 

**$ 12.74** 

**$ 0.24** 

**$ 72.82** 

**$ -**  **$ -**  **$**



### 14 **13 OE Transmission Assembly (brokeout for eCVT only, included in** 

**subsystem roll-ups in base analysis) -**  **$ 58.49** 

**$ 44.17** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 102.66** 

**$ -**  **$ -**  **$**


### 15 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 16 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 17 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 18 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 4 

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



## Baseline

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

## NA **Ford Fiesta Ford Focus**  **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5** Subsystem 

### Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItem 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

# 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)

19 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 20 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -**  **$ -**  **$** 

### 1,010.34 **$ 331.85** 

**$ 532.55** 

**$ 1,874.73** 

**$ 17.46** 

**$ 127.56** 

**$ 132.73** 

**$ 57.79** 

**$ 335.54** 

**$ 6.16** 

**$ 2,216.43** 

**$ 236.07**  **$ 250.33**  **$ 2214.93**  

### SYSTEM ROLL-UP

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 4 

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



# 010000A **Integrated Motor/Generator A ssembly** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **05**Subsystem 

# SYSTEM & SUBSYSTEM DESCRIPTIONItem 

### Ford Fusion **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)**

**- $**  **- $**  **- $**  **- $**  **156.84 $**  **144.79 $**  **138.65 $**  **161.75 $**  Includes Main Cases (Motor/Portion of Electronics and Clutch)

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **104.61 $**  **98.86 $**  **99.30 $**  **114.75 $**  Includes Dual Mass Fly Wheel and Clutch 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

6 **06** 7 **07** 8 **08A** 9 **08B** 10 **09** 11 **10** 12 **11** 13 **12**

14 **13**
15 **0** 16 **0** 17 **0 37.61** 

**$ 35.25**  **$ 33.97**  **$ 40.44**  **$** Oil Pump, Mounting and Drive Pump for IMGA and Cooling Plate/Cover

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  

### 18 **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: 8/30/2012 DRAFTSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTIONItem



### 19 **0** 20 **0 Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)** 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $** 



### 299.05 **$ 278.90**  **$ 271.93**  **$ 316.94**  **$**

**BASE DELTA** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 6 

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

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

# 030000 Body

**Sy stem** 

1 **01 Body Structure Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 2 **02 Front End Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 3 **03 Body Closures Subsystem**  **9.04 $**  **4.24**

**$ 3.65** 

**$ 16.94** 

**$ 0.18** 

**$ 2.24** 

**$ 2.13** 

**$ 0.67** 

**$ 5.22** 

**$ -** 

**$ 22.16** 

**$ -** 

**$ -** 

**$ -** 

**$ 7.31** 

**$ 2.75** 

**$ 2.61** 

**$ 12.67** 

**$** 

### 4 **04 Second Unit Body Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **05 Interior Trim and Ornamentation Subsystem**  **4.74 $**  **1.00**

**$ 1.03** 

**$ 6.77** 

**$ 0.04** 

**$ 0.52** 

**$ 0.48** 

**$ 0.18** 

**$ 1.22** 

**$ -** 

**$ 7.99** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

-Split HEV Technology **Vehicle Class:**Mid to Large Size Passenger Vehicle, 4

-6 Passengers 

# Study Case#:0502(N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **06 Sound and Heat Control Subsystem (Body)**  **5.21 $**  **3.10**

**$ 1.66** 

**$ 9.98** 

**$ 0.08** 

**$ 1.05** 

**$ 0.97** 

**$ 0.32** 

**$ 2.42** 

**$ 0.17** 

**$ 12.57** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 7 **07 Sealing Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 8 **10 Seating Subsystem**  **13.77 $**  **9.76**

**$ 6.72** 

**$ 30.24** 

**$ 0.29** 

**$ 3.83** 

**$ 3.53** 

**$ 1.09** 

**$ 8.75** 

**$ -** 

**$ 38.99** 

**$ -** 

**$ -** 

**$ -** 

**$ 17.57** 

**$ 15.28** 

**$ 12.28** 

**$ 45.13** 

**$** 

### 9 **12 Instrument Panel and Console Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 10 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

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

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

Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

**32.76 $**  **18.10**

**$ 13.06** 

**$ 63.92** 

**$ 0.59** 

**$ 7.64** 

**$ 7.11** 

**$ 2.27** 

**$ 17.62** 

**$ 0.17** 

**$ 81.71** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 24.88

**$ 18.04** 

**$ 14.89** 

**$ 57.81** 

**$ SYSTEM ROLL-UP** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

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



# 030000 Body

**Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **05**ItemSubsystem 

# 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

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

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

6 **06** 7 **07** 8 **10** 9 **12** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0** 18 **0** 19 **0 -** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

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

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

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

**0.60 $**  **7.67**

**$ 7.13** 

**$ 2.19** 

**$ 17.59** 

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**$ 6.31** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

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



# 030000 Body

**Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **05**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **4.96 $**  **5.43 $**  **5.68 $**  **5.82 $**  **5.43 $**  **6.66 $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **7.64 $**  **7.90 $**  **8.03 $**  **8.16 $**  **7.90 $**  **8.42 $**  **Investment(X1 000)**  

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

6 **06** 7 **07** 8 **10** 9 **12** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0** 18 **0** 19 **0 -** 

**$ 11.30**  **$ 12.38**  **$ 12.93**  **$ 13.26**  **$ 12.38**  **$ 15.16**  **$**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **(17.77) $**  **(19.46) $**  **(20.34) $**  **(20.85) $**  **(19.46) $**  **(23.84) $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

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### 19 **0** 20 **0 -** 

**$ -**  **$ -**  **$ -**  **$ -**  **$ -**  **$ -**  **$**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8) Investment(X1**  **000)** 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**- $**  

### 6.13 **$ 6.25**  **$ 6.30**  **$ 6.39**  **$ 6.25**  **$ 6.39**  **$**

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 6 

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

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

# 06 **Brake Sy stem** 

1 **03 Front Rotor Subsystems**  **- $**  **-**

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### 2 **04 Rear Rotor Subsystems**  **- $**  **-**

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### 3 **05 Parking Brake and Actuation Subsystem**  **- $**  **-**

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### 4 **06 Brake Actuation Subsystem**  **43.46 $**  **17.00**

**$ 21.17** 

**$ 81.63** 

**$ 1.02** 

**$ 8.71** 

**$ 7.29** 

**$ 2.19** 

**$ 19.20** 

**$ 0.29** 

**$ 101.12** 

**$ -** 

**$ -** 

**$ -** 

**$ 7.13** 

**$ 3.44** 

**$ 7.43** 

**$ 18.01** 

**$** 

### 5 **07 Power Brake Subsystem (for Hydraulic)**  **48.11 $**  **34.24**

**$ 44.27** 

**$ 126.63** 

**$ 0.74** 

**$ 10.32** 

**$ 9.01** 

**$ 3.19** 

**$ 23.26** 

**$ 0.22** 

**$ 150.11** 

**$ -** 

**$ -** 

**$ -** 

**$ 6.95** 

**$ 6.47** 

**$ 5.07** 

**$ 18.49** 

**$** 

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

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

### Subsystem Description **Investment (X1000)**  Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# 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)** 

# Technology**Level:** Power

-Split HEV Technology **Vehicle Class:**Mid to Large Size Passenger Vehicle, 4

-6 Passengers 

# Study Case#:0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **09 Brake Controls Subsystem**  **21.96 $**  **0.62**

**$ 2.10** 

**$ 24.68** 

**$ 0.12** 

**$ 1.60** 

**$ 1.48** 

**$ 0.62** 

**$ 3.82** 

**$ -** 

**$ 28.50** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

**$** 

### 7 **10 Auxillary Brake Subsystem**  **- $**  **-**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

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

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

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

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

### Subsystem Description **Investment (X1000)**  Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# 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)** 

# 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)

20 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

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### 113.54 **$ 51.86** 

**$ 67.54** 

**$ 232.93** 

**$ 1.88** 

**$ 20.63** 

**$ 17.78** 

**$ 6.00** 

**$ 46.29** 

**$ 0.51** 

**$ 279.73** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 14.08

**$ 9.91** 

**$ 12.51** 

**$ 36.50** 

**$ SYSTEM ROLL-UP** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

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



# 06 **Brake Sy stem** 

1 **03** 2 **04** 3 **05** 4 **06** 5 **07**ItemSubsystem 

# 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

**- $**  **-**

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**$ 1.06** 

**$ 0.40** 

**$ 2.64** 

**$ 0.10** 

**$ 20.75** 

**$ -** 

**$ -** 

**$ -** 

**$ 36.33** 

**$ 13.56** 

**$ 13.74** 

**$ 63.62** 

**$ 0.94** 

**$ 7.59** 

**$ 6.23** 

**$ 1.79** 

**$ 16.55** 

**$ 0.20** 

**$ 80.37** 

**$ -** 

**$ -** 

**$ 0.10**  **$ 1.34** 

**$ 1.21** 

**$ 0.47** 

**$ 3.12** 

**$ 0.02** 

**$ 21.63** 

**$ -** 

**$ -** 

**$ -** 

**$ 41.16** 

**$ 27.77** 

**$ 39.20** 

**$ 108.13** 

**$ 0.64** 

**$ 8.98** 

**$ 7.80** 

**$ 2.72** 

**$ 20.14** 

**$ 0.20** 

**$ 128.48** 

**$ -** 

**$ -** 

**$** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **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**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)**



### 6 **09** 7 **10** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0** 18 **0** 19 **0 -** 

**$ -** 

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**$ 21.96** 

**$ 0.62** 

**$ 2.10** 

**$ 24.68** 

**$ 0.12** 

**$ 1.60** 

**$ 1.48** 

**$ 0.62** 

**$ 3.82** 

**$ -** 

**$ 28.50** 

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### 19 **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 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** End Item

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **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**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)**

**- $**  **-**

**$ -** 

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### 0.18 **$ 2.45** 

**$ 2.27** 

**$ 0.87** 

**$ 5.76** 

**$ 0.12** 

**$ 42.39** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 99.45

**$ 41.94** 

**$ 55.03** 

**$ 196.43** 

**$ 1.70** 

**$ 18.18** 

**$ 15.51** 

**$ 5.13** 

**$ 40.52** 

**$ 0.40** 

**$ 237.35** 

**$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

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



# 06 **Brake Sy stem** 

1 **03** 2 **04** 3 **05** 4 **06** 5 **07**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **80.37 $**  **80.37 $**  **80.37 $**  **80.37 $**  **80.37 $**  **80.37 $** 

**- $**  **116.97 $**  **121.87 $**  **125.54 $**  **126.20 $**  **123.91 $**  **132.12 $**  **Investment(X1 000)**  

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

6 **09** 7 **10** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0** 18 **0** 19 **0 -** 

**$ 28.50**  **$ 28.50**  **$ 28.50**  **$ 28.50**  **$ 28.50**  **$ 28.50**  **$**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

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**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

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### 19 **0 $**  **$ $**  **$ $**  **$ $** 



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** 

## Baseline

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8) Investment(X1**  **000)** 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  

### 225.84 **$ 230.74**  **$ 234.42**  **$ 235.07**  **$ 232.78**  **$ 240.99**  **$**

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 6 

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

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

# 12 **Climate Control Sy stem** 

1 **01 Air Handling/Body Ventilation Subsystem**  **- $**  **-**

**$ -** 

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### 2 **02 Heating Defrosting Subsystem**  **27.27 $**  **5.36**

**$ 5.27** 

**$ 37.90** 

**$ 0.27** 

**$ 2.87** 

**$ 3.09** 

**$ 1.42** 

**$ 7.65** 

**$ 0.15** 

**$ 45.70** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

**$** 

### 3 **03 Refrigeration/Air Conditioning Subsystem**  **148.86 $**  **23.69**

**$ 43.32** 

**$ 215.88** 

**$ 1.85** 

**$ 14.58** 

**$ 13.38** 

**$ 5.46** 

**$ 35.27** 

**$ -** 

**$ 251.15** 

**$ -** 

**$ -** 

**$ -** 

**$ 24.10** 

**$ 18.98** 

**$ 25.92** 

**$ 68.99** 

**$** 

### 4 **04 Controls Subsystem**  **- $**  **-**

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### 5 **0 NA**  **- $**  **-**

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**$** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

-Split HEV Technology **Vehicle Class:**Mid to Large Size Passenger Vehicle, 4

-6 Passengers 

# Study Case#:0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **0 NA**  **- $**  **-**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

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

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

Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

20 **0 NA**  **- $**  **-**

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### 176.13 **$ 29.05** 

**$ 48.59** 

**$ 253.77** 

**$ 2.12** 

**$ 17.45** 

**$ 16.47** 

**$ 6.88** 

**$ 42.92** 

**$ 0.15** 

**$ 296.85** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 24.10

**$ 18.98** 

**$ 25.92** 

**$ 68.99** 

**$ SYSTEM ROLL-UP** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

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



# 12 **Climate Control Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **0**ItemSubsystem 

# 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

**- $**  **-**

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**$ 5.36** 

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**$ 2.87** 

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**$ 1.42** 

**$ 7.65** 

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**$ 4.72** 

**$ 17.40** 

**$ 146.88** 

**$ 1.27** 

**$ 8.10** 

**$ 7.86** 

**$ 3.57** 

**$ 20.80** 

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**$ 167.68** 

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

6 **0** 7 **0** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0**

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### 19 **0 -** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** End Item

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

**- $**  **-**

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### 0.58 **$ 6.48** 

**$ 5.53** 

**$ 1.89** 

**$ 14.47** 

**$ -** 

**$ 83.47** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### ###### **10.07 $**  **22.67**

**$ 184.78** 

**$ 1.54** 

**$ 10.97** 

**$ 10.95** 

**$ 5.00** 

**$ 28.45** 

**$ 0.15** 

**$ 213.38** 

**$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

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



# 12 **Climate Control Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **0**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **41.16 $**  **43.62 $**  **46.81 $**  **58.03 $**  **53.35 $**  **51.42 $** 

**- $**  **149.56 $**  **158.88 $**  **170.96 $**  **213.45 $**  **195.71 $**  **188.42 $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

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

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

6 **0** 7 **0** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** 

## Baseline

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8) Investment(X1**  **000)** 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  

### 190.72 **$ 202.51**  **$ 217.77**  **$ 271.48**  **$ 249.05**  **$ 239.85**  **$**

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 6 

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

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

# 14**Electrical Pow er Supply**  **Sy stem** 

1 **01 Service Battery Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

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**$ 3.00** 

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**$** 

### 2 **02 Generator/Alternator and Regulator Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

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**$ 29.50** 

**$ 11.05** 

**$ 27.95** 

**$ 68.50** 

**$** 

### 3 **03 High Voltage Traction Battery Subsystem**  **1,294.46 $**  **170.68**

**$ 293.87** 

**$ 1,759.01** 

**$ 13.57** 

**$ 119.20** 

**$ 128.32** 

**$ 61.13** 

**$ 322.21** 

**$ 3.95** 

**$ 2,085.17** 

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### 4 **05 Voltage Converter / Inverter Subsystem**  **89.13 $**  **19.62**

**$ 21.83** 

**$ 130.58** 

**$ 0.65** 

**$ 8.49** 

**$ 7.82** 

**$ 3.24** 

**$ 20.21** 

**$ 0.13** 

**$ 150.91** 

**$ -** 

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### 5 **08 Energy Management Module Subsystem**  **- $**  **-**

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**$** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

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

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

Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

20 **0 NA**  **- $**  **-**

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### ######## **190.29**

**$ 315.70** 

**$ 1,889.58** 

**$ 14.22** 

**$ 127.69** 

**$ 136.14** 

**$ 64.37** 

**$ 342.41** 

**$ 4.08** 

**$ 2,236.08** 

**$ -** 

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**$** 

### 32.50

**$ 11.05** 

**$ 27.95** 

**$ 71.50** 

**$ SYSTEM ROLL-UP** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

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



# 14**Electrical Pow er Supply**  **Sy stem** 

1 **01** 2 **02** 3 **03** 4 **05** 5 **08**ItemSubsystem 

# 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

**0.02 $**  **0.20**

**$ 0.18** 

**$ 0.08** 

**$ 0.47** 

**$ -** 

**$ 3.47** 

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**$ 0.33**  **$ 4.23** 

**$ 3.90** 

**$ 1.63** 

**$ 10.08** 

**$ 0.13** 

**$ 78.70** 

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**$ (29.50)** 

**$ (11.05)** 

**$ (27.95)** 

**$ (68.50)** 

**$ (0.33)** 

**$ (4.23)** 

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**$ (1.63)** 

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**$ (78.70)** 

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**$ 1,294.46** 

**$ 170.68** 

**$ 293.87** 

**$ 1,759.01** 

**$ 13.57** 

**$ 119.20** 

**$ 128.32** 

**$ 61.13** 

**$ 322.21** 

**$ 3.95** 

**$ 2,085.17** 

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**$ 89.13** 

**$ 19.62** 

**$ 21.83** 

**$ 130.58** 

**$ 0.65** 

**$ 8.49** 

**$ 7.82** 

**$ 3.24** 

**$ 20.21** 

**$ 0.13** 

**$ 150.91** 

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

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

6 **0** 7 **0** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0**

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### 19 **0 -** 

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**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** End Item

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 0.34 **$ 4.42** 

**$ 4.08** 

**$ 1.70** 

**$ 10.54** 

**$ 0.13** 

**$ 82.17** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### ######## **179.24 $**  **287.75**

**$ 1,818.08** 

**$ 13.88** 

**$ 123.27** 

**$ 132.06** 

**$ 62.67** 

**$ 331.87** 

**$ 3.96** 

**$ 2,153.91** 

**$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

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



# 14**Electrical Pow er Supply**  **Sy stem** 

1 **01** 2 **02** 3 **03** 4 **05** 5 **08**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)**

**- $**  **(3.47) $**  **(3.47) $**  **(3.47) $**  **(3.47) $**  **(3.47) $**  **(3.47) $** 

**- $**  **(56.92) $**  **(61.23) $**  **(78.70) $**  **(82.72) $**  **(82.72) $**  **(90.55) $** 

**- $**  **1,761.69 $**  **2,041.44 $**  **2,213.21 $**  **2,213.23 $**  **2,143.59 $**  **2,491.96 $** 

**- $**  **111.86 $**  **121.98 $**  **152.31 $**  **162.43 $**  **162.43 $**  **177.59 $** 

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

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

6 **0** 7 **0** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0**

18 **0 -** 

**$ -**  **$ -**  **$ -**  **$ -**  **$ -**  **$ -**  **$**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

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**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 



### 19 **0 -** 

**$ -**  **$ -**  **$ -**  **$ -**  **$ -**  **$ -**  **$ -**  **$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** 

## Baseline

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8) Investment(X1**  **000)** 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  

### 1,813.17 **$ 2,098.72**  **$ 2,283.36**  **$ 2,289.47**  **$ 2,219.83**  **$ 2,575.53**  **$**

1010.737941 1107.366219 1374.881823 1317.229414 1126.326268 1454.240372



# AltenatorScaling: 110 amp

-Feista $56.92 120amp

-Focus (297.99 Service OAR) = $61.23 150amp

-Fusion (381.99 Service OAR) = $78.70 (From Cost Sheet) 160 amp

-Flex, Explorer 175 amp

-F150 = $90.55

*********************************************************************** $381.99 Service/$78.70 Cal = 4.85 mark

-up Therefore 120amp = $297.99/4.85= $61.23 *********************************************************************** Average Cost Per Amp $ 0.517 Average (($61.23/120amp+$78.70/150amp) Therefore for 110, 160 and 175.... = 110*$0.517/amp= $56.92 =160*$0.517/amp= $82.72 =175*$0.517/amp= $90.55

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 6 

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

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

# 14**Electrical Pow er Supply**  **Sy stem** 

1 **01 Service Battery Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 3.00** 

**$ -** 

**$ -** 

**$ 3.00** 

**$** 

### 2 **02 Generator/Alternator and Regulator Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 29.50** 

**$ 11.05** 

**$ 27.95** 

**$ 68.50** 

**$** 

### 3 **03 High Voltage Traction Battery Subsystem**  **1,294.46 $**  **170.68**

**$ 293.87** 

**$ 1,759.01** 

**$ 13.57** 

**$ 119.20** 

**$ 128.32** 

**$ 61.13** 

**$ 322.21** 

**$ 3.95** 

**$ 2,085.17** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 4 **05 Voltage Converter / Inverter Subsystem**  **89.13 $**  **19.62**

**$ 21.83** 

**$ 130.58** 

**$ 0.65** 

**$ 8.49** 

**$ 7.82** 

**$ 3.24** 

**$ 20.21** 

**$ 0.13** 

**$ 150.91** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **08 Energy Management Module Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

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

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

### Subsystem Description **Investment (X1000)**  Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# 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)** 

# Technology**Level:** Power

-Split HEV Technology **Vehicle Class:**Mid to Large Size Passenger Vehicle, 4

-6 Passengers 

# Study Case#:0502(N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 7 **0 NA**  **- $**  **-**

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### 15 **0 NA**  **- $**  **-**

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### 16 **0 NA**  **- $**  **-**

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### 18 **0 NA**  **- $**  **-**

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### 19 **0 NA**  **- $**  **-**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

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

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

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

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

### Subsystem Description **Investment (X1000)**  Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# 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)** 

# 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)

20 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### ######## **190.29**

**$ 315.70** 

**$ 1,889.58** 

**$ 14.22** 

**$ 127.69** 

**$ 136.14** 

**$ 64.37** 

**$ 342.41** 

**$ 4.08** 

**$ 2,236.08** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 32.50

**$ 11.05** 

**$ 27.95** 

**$ 71.50** 

**$ SYSTEM ROLL-UP** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

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



# 14**Electrical Pow er Supply**  **Sy stem** 

1 **01** 2 **02** 3 **03** 4 **05** 5 **08**ItemSubsystem 

# 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

**0.02 $**  **0.20**

**$ 0.18** 

**$ 0.08** 

**$ 0.47** 

**$ -** 

**$ 3.47** 

**$ -** 

**$ -** 

**$ -** 

**$ (3.00)** 

**$ -** 

**$ -** 

**$ (3.00)** 

**$ (0.02)** 

**$ (0.20)** 

**$ (0.18)** 

**$ (0.08)** 

**$ (0.47)** 

**$ -** 

**$ (3.47)** 

**$ -** 

**$ -** 

**$ 0.33**  **$ 4.23** 

**$ 3.90** 

**$ 1.63** 

**$ 10.08** 

**$ 0.13** 

**$ 78.70** 

**$ -** 

**$ -** 

**$ -** 

**$ (29.50)** 

**$ (11.05)** 

**$ (27.95)** 

**$ (68.50)** 

**$ (0.33)** 

**$ (4.23)** 

**$ (3.90)** 

**$ (1.63)** 

**$ (10.08)** 

**$ (0.13)** 

**$ (78.70)** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 1,294.46** 

**$ 170.68** 

**$ 293.87** 

**$ 1,759.01** 

**$ 13.57** 

**$ 119.20** 

**$ 128.32** 

**$ 61.13** 

**$ 322.21** 

**$ 3.95** 

**$ 2,085.17** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 89.13** 

**$ 19.62** 

**$ 21.83** 

**$ 130.58** 

**$ 0.65** 

**$ 8.49** 

**$ 7.82** 

**$ 3.24** 

**$ 20.21** 

**$ 0.13** 

**$ 150.91** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **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**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)**



### 6 **0** 7 **0** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0**

18 **0 -** 

**$ -** 

**$ -** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** End Item

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **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**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

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### 0.34 **$ 4.42** 

**$ 4.08** 

**$ 1.70** 

**$ 10.54** 

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**$ 82.17** 

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### ######## **179.24 $**  **287.75**

**$ 1,818.08** 

**$ 13.88** 

**$ 123.27** 

**$ 132.06** 

**$ 62.67** 

**$ 331.87** 

**$ 3.96** 

**$ 2,153.91** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

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



# 14**Electrical Pow er Supply**  **Sy stem** 

1 **01** 2 **02** 3 **03** 4 **05** 5 **08**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)**

**- $**  **(3.47) $**  **(3.47) $**  **(3.47) $**  **(3.47) $**  **(3.47) $**  **(3.47) $** 

**- $**  **(56.92) $**  **(61.23) $**  **(78.70) $**  **(82.72) $**  **(82.72) $**  **(90.55) $** 

**- $**  **1,202.24 $**  **1,333.93 $**  **1,442.29 $**  **1,442.54 $**  **1,398.15 $**  **1,619.13 $** 

**- $**  **111.86 $**  **121.98 $**  **152.31 $**  **162.43 $**  **162.43 $**  **177.59 $** 

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

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

6 **0** 7 **0** 8 **0** 9 **0** 10 **0** 11 **0** 12 **0** 13 **0** 14 **0** 15 **0** 16 **0** 17 **0**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0** 

## Baseline

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8) Investment(X1**  **000)** 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  

### - **$ 1,253.72**  **$ 1,391.21**  **$ 1,512.44**  **$ 1,518.78**  **$ 1,474.39**  **$ 1,702.71**  **$**



# AltenatorScaling: 110 amp

-Feista $56.92 120amp

-Focus (297.99 Service OAR) = $61.23 150amp

-Fusion (381.99 Service OAR) = $78.70 (From Cost Sheet) 160 amp

-Flex, Explorer 175 amp

-F150 = $90.55

*********************************************************************** $381.99 Service/$78.70 Cal = 4.85 mark

-up Therefore 120amp = $297.99/4.85= $61.23 *********************************************************************** Average Cost Per Amp $ 0.517 Average (($61.23/120amp+$78.70/150amp) Therefore for 110, 160 and 175.... = 110*$0.517/amp= $56.92 =160*$0.517/amp= $82.72 =175*$0.517/amp= $90.55

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 6 

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

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

# 18 **Electrical Distribution and Electronic Control Sy stem** 

1 **01 Electrical Wiring and Circuit Protection Subsystem**  **- $**  **-**

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### 4 **06 Traction And High Voltage Power Distribution Subsystem**  **127.00 $**  **32.43**

**$ 16.16** 

**$ 175.58** 

**$ 0.81** 

**$ 10.64** 

**$ 9.75** 

**$ 4.03** 

**$ 25.23** 

**$ 0.68** 

**$ 201.50** 

**$ -** 

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### 5 **07 Power Electric Center (PEC) Subsystem**  **- $**  **-**

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**$** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

-Split HEV Technology **Vehicle Class:**Mid to Large Size Passenger Vehicle, 4

-6 Passengers 

# Study Case#:0502(N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **0 NA**  **- $**  **-**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

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

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

Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem **System ED&T/R&D**  **(x1000)** 

### 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) Investment** 

**(X1000)** 

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

**127.00 $**  **32.43**

**$ 16.16** 

**$ 175.58** 

**$ 0.81** 

**$ 10.64** 

**$ 9.75** 

**$ 4.03** 

**$ 25.23** 

**$ 0.68** 

**$ 201.50** 

**$ -** 

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### -

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**$ SYSTEM ROLL-UP** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

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



# 18 **Electrical Distribution and Electronic Control Sy stem** 

1 **01** 2 **03** 3 **04** 4 **06** 5 **07**ItemSubsystem 

# 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

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**$ 25.23** 

**$ 0.68** 

**$ 201.50** 

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

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

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

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

**Component/ Assembly**  **Cost Impact to OEM**  **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# 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**

**- $**  **-**

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### ###### **32.43 $**  **16.16**

**$ 175.58** 

**$ 0.81** 

**$ 10.64** 

**$ 9.75** 

**$ 4.03** 

**$ 25.23** 

**$ 0.68** 

**$ 201.50** 

**$ -** 

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

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



# 18 **Electrical Distribution and Electronic Control Sy stem** 

1 **01** 2 **03** 3 **04** 4 **06** 5 **07**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8)**

**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

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**- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $**  **- $** 

**- $**  **- $**  **197.11 $**  **201.22 $**  **203.28 $**  **203.97 $**  **201.22 $**  **212.20 $** 

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

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

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### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

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

# SYSTEM & SUBSYSTEM DESCRIPTION **Baseline**

**NA Ford Fiesta**  **Ford Focus Ford Fusion**  **Ford Flex Ford Explore**  **(3.5L V6) Ford F150**  **(6.2L V8) Investment(X1**  **000)** 

## Calculated Incremental Manufacturing Cost - P2 HEV Technology

**2010 Ford Fusion Power split HEV**  **Sub-Compact Vehicle Segment**  **Passenger 2-4 Small/Compact Vehicle**  **Segment Passenger 2-5**  **Mid Size/Vehicle Segment Passenger 4-6**  **Large Size Vehicle Segment**  **Passenger 6-8 Passenger + Midsize** 

**Towing Truck Segment Passenger 5-6**  **Towing 4000-5000lbs (10,000 lb GCWR)**  **Passenger or Commercial**

**Truck with Strong Towing Capabilities**  **Passenger 3-6 Towing 6000-8000lbs**  **(15,000 lb GCWR)**

**- $**  

### - **$ 197.11**  **$ 201.22**  **$ 203.28**  **$ 203.97**  **$ 201.22**  **$ 212.20**  **$**



# AltenatorScaling: 110 amp

-Feista $56.92 120amp

-Focus (297.99 Service OAR) = $61.23 150amp

-Fusion (381.99 Service OAR) = $78.70 (From Cost Sheet) 160 amp

-Flex, Explorer 175 amp

-F150 = $90.55

*********************************************************************** $381.99 Service/$78.70 Cal = 4.85 mark

-up Therefore 120amp = $297.99/4.85= $61.23 *********************************************************************** Average Cost Per Amp $ 0.517 Average (($61.23/120amp+$78.70/150amp) Therefore for 110, 160 and 175.... = 110*$0.517/amp= $56.92 =160*$0.517/amp= $82.72 =175*$0.517/amp= $90.55

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411