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 a

Updated Curb Weight Reductions & Li-Ion Battery: EPA File 0419

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 Vehic
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 (LiPolymer) $ 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 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

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 sco

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 (LiPolymer) $ 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)

High Voltage Distribution

Electric 

Motor/Generator

Flywheel

Clutch Clutch & Motor Cooling

Power Electronics/Inverter 

& Controls

Electric Motor/Generator Clutch Assembly

High Voltage Traction Battery

P2 System Boundary

Systems Requiring 

Modifications

High Voltage Distribution

Battery Cells/Modules

Control 

Electronics, 

Sensors, 

Switches

Battery Cooling Module

Relays, 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

t - P2 HEV Technology

e the scope of this analysis

PA 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

rom 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

t - 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 

Engine technology selection and downsizing outside of a
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

t - P2 HEV Technology

utside of analysis scope 

ng 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 

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 Veh

Passenger 6

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 
$ 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

t - 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 Vehi

Passenger 6-

Vehicle Example Ford Fiesta Ford Focus Ford Fusion and 

Taurus Ford Flex

System

 ID System Description

Calculated Incremental Manufacturing Cost - 

$ (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 Vehi

Passenger 6-

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 (LiPolymer) $ 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

.g. AT, ATM, DCT)

raction Battery

Internal Combustion Engine 

(ICE)

High Voltage Distribution

Electric 

Motor/Generator

Flywheel

Clutch Clutch & Motor Cooling

Power Electronics/Inverter 

& Controls

Electric Motor/Generator Clutch Assembly

 Body System 

 P2 System Boundary

 Systems Requiring 

Modifications

Battery Cells/Modules

Cooling Module

raction Battery

High Voltage Distribution

 Body System 

 Brake System

 Climate Control System
Baseline 

2010 Ford Fusion Pow

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 $ 
i Van Vehicle 

Segment

ssenger 6-8

Small Truck Large Truck

Ford Flex Ford Ranger Ford Explorer

- $ - $ -

1,190.83 $ 1,159.44 $ 1,274.14

ng Cost - P2 HEV Technology

sizing 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

wnsizing 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

facturing 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

acturing 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 Module

Relays, Fuses,

Disconnect

High Voltage Traction Battery
Baseline 

ord Fusion Powersplit 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 a

Updated Curb Weight Reductions & Li-Ion Battery: EPA File 0419

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 Vehic
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 (LiPolymer) $ 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 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

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 sco

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 (LiPolymer) $ 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)

High Voltage Distribution

Electric 

Motor/Generator

Flywheel

Clutch Clutch & Motor Cooling

Power Electronics/Inverter 

& Controls

Electric Motor/Generator Clutch Assembly

High Voltage Traction Battery

P2 System Boundary

Systems Requiring 

Modifications

High Voltage Distribution

Battery Cells/Modules

Control 

Electronics, 

Sensors, 

Switches

Battery Cooling Module

Relays, 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

t - P2 HEV Technology

e the scope of this analysis

PA 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

rom 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

t - P2 HEV Technology

Sub-Compact 

Vehicle 

Segment

Passenger 2-4

Small/ Compact 

Vehicle 

Segment 

Passenger 2-5

System

 ID System Description

Calculated Incremental M

20% Curb Weight Reduction Across A
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

t - P2 HEV Technology

utside of analysis scope 

ng outside of analysis scope

Vehicle Example Ford Fiesta Ford Focus Ford Fu

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 selectio

Transmission technology sele

Sub-Compact 

Vehicle 

Segment

Passenger 2-4

Small/Compact 

Vehicle 

Segment 

Passenger 2-5

System

 ID System Description

Calculated Incremental M

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 Fu

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 M
$ 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

t - P2 HEV Technology

Sub-Compact 

Vehicle 

Segment

Passenger 2-4

Small/Compact 

Vehicle 

Segment 

Passenger 2-5

Vehicle Example Ford Fiesta Ford Focus Ford Fu

H

Electric Power Supply System

(Sum of Subsystems 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 M

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

(Sum of Subsystems 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

.g. AT, ATM, DCT)

raction Battery

Internal Combustion Engine 

(ICE)

High Voltage Distribution

Electric 

Motor/Generator

Flywheel

Clutch Clutch & Motor Cooling

Power Electronics/Inverter 

& Controls

Electric Motor/Generator Clutch Assembly

 Body System 

 P2 System Boundary

 Systems Requiring 

Modifications

Battery Cells/Modules

Cooling Module

raction Battery

High Voltage Distribution

 Body System 

 Brake System

 Climate Control System
Baseline 

2010 Ford Fusion Pow

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

emental Manufacturing Cost - P2 HEV Technology

oss 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

gy selection and downsizing outside of analysis scope 

nology 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

emental 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

emental 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)

emental 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 Module

Relays, Fuses,

Disconnect

High Voltage Traction Battery
Baseline 

ord Fusion Powersplit 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 System

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)

Item

Subsystem

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)

Item

Subsystem

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 System

1 00

2 02

3 03

4 04

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ 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) $ -

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

19 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

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

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

$ 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 System

1 00

2 02

3 03

4 04

5 05

Item

Subsystem

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

DRAFT

Item

Subsystem

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 Assembly

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 DESCRIPTION

Item

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

S

 (6.2L V8) ubsystem

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

Item

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

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 Assembly

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 - P

2010 Ford Fusion Powersplit HEV

Sub-Compact Vehicle 

Segment

Passenger 2-4

Small/Compact Vehicle 

Segment 

Passenger 2-5

Subsystem

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

Item

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 - P

2010 Ford Fusion Powersplit HEV

Sub-Compact Vehicle 

Segment

Passenger 2-4

Small/Compact Vehicle 

Segment 

Passenger 2-5

Subsystem

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

Item

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 Assembly

1 01

2 02

3 03

4 04

5 05

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Item

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

DRAFT

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Item

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 System

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)

Item

Subsystem

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

20 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 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)

Item

Subsystem

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

SYSTEM ROLL-UP $ 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

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 System

1 01

2 02

3 03

4 04

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

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

$ 0.14 $ 1.69 $ 1.63 $ 0.52 $ 3.97 $ - $ 16.64 $ - $ - $ - $ 1.73 $ 1.49 $ 1.04 $ 4.26 $ 0.04 $ 0.55 $ 0.51 $ 0.16 $ 1.26 $ - $ 5.52 $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 5.21 $ 3.10 $ 1.66 $ 9.98 $ 0.08 $ 1.05 $ 0.97 $ 0.32 $ 2.42 $ 0.17 $ 12.57 $ - $ -

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

$ 0.46 $ 5.98 $ 5.51 $ 1.68 $ 13.62 $ - $ 58.75 $ - $ - $ - $ (3.81) $ (5.53) $ (5.56) $ (14.89) $ (0.16) $ (2.15) $ (1.97) $ (0.58) $ (4.87) $ - $ (19.76) $ - $ -

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

20 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

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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 $ - $ 75.39 $ - $ - $ - $ 7.87 $ 0.07 $ (1.82) $ 6.12 $ (0.00) $ (0.02) $ (0.02) $ 0.08 $ 0.03 $ 0.17 $ 6.31 $ - $ -

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 System

1 01

2 02

3 03

4 04

5 05

Item

Subsystem

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 Powersplit 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)

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ -

20 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

DRAFT

Item

Subsystem

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 Powersplit 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 System

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

2 04 Rear Rotor Subsystems $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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 TECHNOLO

2010 Ford Fusion, 3.0L 

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)

Item

Subsystem

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

7 10 Auxillary Brake Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 Na $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 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 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 TECHNOLO

2010 Ford Fusion, 3.0L 

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)

Item

Subsystem

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

SYSTEM ROLL-UP $ 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

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 System

1 03

2 04

3 05

4 06

5 07

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

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

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

$ 0.08 $ 1.11 $ 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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 21.96 $ 0.62 $ 2.10 $ 24.68 $ 0.12 $ 1.60 $ 1.48 $ 0.62 $ 3.82 $ - $ 28.50 $ - $ -

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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)

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

$ 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 System

1 03

2 04

3 05

4 06

5 07

Item

Subsystem

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 Powersplit 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

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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 Powersplit 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 System

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

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

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

5 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

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 TECHNOLO

2010 Ford Fusion, 3.0L 

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

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 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 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)

Item

Subsystem

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 TECHNOLO

2010 Ford Fusion, 3.0L 

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

SYSTEM ROLL-UP $ 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

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 System

1 01

2 02

3 03

4 04

5 0

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 27.27 $ 5.36 $ 5.27 $ 37.90 $ 0.27 $ 2.87 $ 3.09 $ 1.42 $ 7.65 $ 0.15 $ 45.70 $ - $ -

$ 0.58 $ 6.48 $ 5.53 $ 1.89 $ 14.47 $ 83.47 $ - $ - $ - $ 124.76 $ 4.72 $ 17.40 $ 146.88 $ 1.27 $ 8.10 $ 7.86 $ 3.57 $ 20.80 $ - $ 167.68 $ - $ -

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

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

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

18 0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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

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

$ 0.58 $ 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 System

1 01

2 02

3 03

4 04

5 0

Item

Subsystem

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 Powersplit 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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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 Powersplit 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 Power Supply System

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

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

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 TECHNOL

2010 Ford Fusion, 3.0

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

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 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 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)

Item

Subsystem

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 TECHNOL

2010 Ford Fusion, 3.0

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

SYSTEM ROLL-UP ######## $ 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

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 Power Supply System

1 01

2 02

3 03

4 05

5 08

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ 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 $ - $ -

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

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

18 0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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 Power Supply System

1 01

2 02

3 03

4 05

5 08

Item

Subsystem

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 Powersplit 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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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 Powersplit 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

Altenator Scaling: 

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 Power Supply System

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 TECHNOL

2010 Ford Fusion, 3.0

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)

Item

Subsystem

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

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 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 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 TECHNOL

2010 Ford Fusion, 3.0

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)

Item

Subsystem

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

SYSTEM ROLL-UP ######## $ 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

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 Power Supply System

1 01

2 02

3 03

4 05

5 08

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ 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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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)

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

$ 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 Power Supply System

1 01

2 02

3 03

4 05

5 08

Item

Subsystem

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 Powersplit 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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DRAFT

Item

Subsystem

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 Powersplit 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

Altenator Scaling: 

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 System

1 01 Electrical Wiring and Circuit Protection Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 03 Electrical Distribution Switches Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 04 Miscellaneous Electrical Devices Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 07 Power Electric Center (PEC) Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

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 TECHNOLO

2010 Ford Fusion, 3.0L 

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

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

20 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 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)

Item

Subsystem

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 TECHNOLO

2010 Ford Fusion, 3.0L 

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)

SYSTEM ROLL-UP $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ - $ - $ - $ - $ - $ -

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 System

1 01

2 03

3 04

4 06 

5 07

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ -

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

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

18 0

19 0

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

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

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

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

20 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

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - ###### $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ -

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 System

1 01

2 03

3 04

4 06 

5 07

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Baseline 

NA Ford Fiesta Ford Focus Ford Fusion Ford Flex Ford Explore 

(3.5L V6)

Ford F150

 (6.2L V8)

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

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

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

$ - $ - $ 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 Powersplit 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

19 0

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

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

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

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ -

20 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

DRAFT

Item

Subsystem

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 Powersplit 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

Altenator Scaling: 

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