Page:1 of 4 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

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

021200 Transmission Cooling Subsystem

1 00 Assembly of Cooling Subsystem $ 0.36 $ - $ - $ 0.36 $ - $ - $ - $ - $ - $ - $ 0.36 Negligible Change 1.00 $ 0.36

2 01 Water Pumps $24.35 $ 3.09 $ 4.49 $ 31.93 $ 0.17 $ 2.36 $ 2.11 $ 0.81 $ 5.46 $ 0.08 $ 37.47

Assume Fusion HEV Trans Cooling Pump 

size would handle single motor, power 

electronics and wet clutch for engaging and 1.00 $ 37.47

Total 

Packaging 

Cost 

(Component

/ Assembly)

Ford Fusion Conversion from e-CVT to 

IMGA

Scaling Parameter Description

Ford Fusion Conversion from e-CVT to 

IMGA

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERA

2010 Ford Fusion, 2.5L Atkinson 

(Motor 60kW, Battery 275V, Nominal 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Parallel HEV Technology

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

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

IMGA to ICE for Large Car Application

3 02 Thermostat Housings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 04 Heat Exchangers $ 4.80 $ 8.09 $ 7.84 $ 20.73 $ 0.18 $ 2.69 $ 2.19 $ 0.58 $ 5.63 $ 0.10 $ 26.46

Assume Fusion HEV Trans Cooling Pump 

size would handle single motor, power 

electronics and wet clutch for engaging and 

IMGA to ICE for Large Car Application

1.00 $ 26.46

5 05 Pressure Regulators $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

6 06 Expansion Tanks $ 2.19 $ 1.46 $ 1.27 $ 4.93 $ 0.04 $ 0.60 $ 0.49 $ 0.14 $ 1.27 $ 0.05 $ 6.25 Negligible Change 1.00 $ 6.25

7 65 Adapters $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 70 Pipes, Hoses, Ducting $ 1.21 $ 0.40 $ 0.29 $ 1.89 $ 0.01 $ 0.21 $ 0.14 $ 0.02 $ 0.37 $ 0.02 $ 2.28 Negligible Change 1.00 $ 2.28

9 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

Material Labor Burden End Item 

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

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Total 

Packaging 

Cost 

(Component

/ Assembly)

Ford Fusion Conversion from e-CVT to 

IMGA

Scaling Parameter Description

Ford Fusion Conversion from e-CVT to 

IMGA

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERA

2010 Ford Fusion, 2.5L Atkinson 

(Motor 60kW, Battery 275V, Nominal 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Parallel HEV Technology

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

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

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

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

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

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

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

$ 32.91 $ 13.04 $ 13.89 $ 59.84 $ 0.40 $ 5.85 $ 4.93 $ 1.55 $ 12.74 $ 0.24 $ 72.82 $ - $ 72.82

Baseline

SUBSYSTEM 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

021200 Transmission Cooling Subsystem

1 00

2 01

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

 Negligible Change 1.00 $ 0.36 1.00 $ 0.36 1.00 $ 0.36 1.00 $ 0.36 1.00 $ 0.36 1.00 $ 0.36

Scale Based on ICE torque to IMGA. Assume 1% Increase/decrease 

in torque results in 0.875% increase/decrease in costs n/a $ 22.19 n/a 25.147 n/a 37.467 n/a 32.352 n/a 32.728 n/a 39.303

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Scaling Parameter(s) Description

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

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)

3 02

4 04

5 05

6 06

7 65

8 70

9 75

10 80

11 85

12 90

13 95

Scale Based on ICE torque to IMGA. Assume 1% Increase/decrease 

in torque results in 0.875% increase/decrease in costs n/a $ 15.68 n/a 17.762 n/a 26.464 n/a 22.852 n/a 23.117 n/a 27.761

$ 6.25 $ 6.25 $ 6.25 $ 6.25 $ 6.25 $ 6.25

$ 2.28 $ 2.28 $ 2.28 $ 2.28 $ 2.28 $ 2.28

$ -

Based on surrogate component capacity versus costs i.e., 

hydraulic pumps, air fans, etc

Approx 1.60xcapacity =1.4xCost

14 99

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

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

0 0

0 0

0 0

0 0

0 0

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Scaling Parameter(s) Description

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

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)

0 0

$ 46.76 $ 51.80 $ 72.82 $ 64.09 $ 64.73 $ 75.95

1 2 3 4 5 6

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

021200 Transmission Cooling Subsystem

1 00 Assembly of Cooling Subsystem $ 0.36 $ - $ - $ 0.36 $ - $ - $ - $ - $ - $ - $ 0.36 $ - $ - $ - $ - $ - $ - $ -

2 01 Water Pumps $24.35 $ 3.09 $ 4.49 $ 31.93 $ 0.17 $ 2.36 $ 2.11 $ 0.81 $ 5.46 $ 0.08 $ 37.47 $ - $ - $ - $ - $ - $ - $ -

3 02 Thermostat Housings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 04 Heat Exchangers $ 4.80 $ 8.09 $ 7.84 $ 20.73 $ 0.18 $ 2.69 $ 2.19 $ 0.58 $ 5.63 $ 0.10 $ 26.46 $ - $ - $ - $ 4.89 $ 8.99 $ 9.19 $ 23.06

5 05 Pressure Regulators $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Investment

(X1000)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

System 

ED&T/R&D

(x1000)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Parallel HEV Technology

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

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

6 06 Expansion Tanks $ 2.19 $ 1.46 $ 1.27 $ 4.93 $ 0.04 $ 0.60 $ 0.49 $ 0.14 $ 1.27 $ 0.05 $ 6.25 $ - $ - $ - $ - $ - $ - $ -

7 65 Adapters $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 70 Pipes, Hoses, Ducting $ 1.21 $ 0.40 $ 0.29 $ 1.89 $ 0.01 $ 0.21 $ 0.14 $ 0.02 $ 0.37 $ 0.02 $ 2.28 $ - $ - $ - $ - $ - $ - $ -

9 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

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

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

0 0 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

Investment

(X1000)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

System 

ED&T/R&D

(x1000)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Parallel HEV Technology

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

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

SUBSYSTEM ROLL-UP $ 32.91 $ 13.04 $ 13.89 $ 59.84 $ 0.40 $ 5.85 $ 4.93 $ 1.55 $ 12.74 $ 0.24 $ 72.82 $ - $ - $ - $ 4.89 $ 8.99 $ 9.19 $ 23.06

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

021200 Transmission Cooling Subsystem

1 00

2 01

3 02

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.36 $ - $ - $ 0.36 $ - $ - $ - $ - $ - $ - $ 0.36 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 24.35 $ 3.09 $ 4.49 $ 31.93 $ 0.17 $ 2.36 $ 2.11 $ 0.81 $ 5.46 $ 0.08 $ 37.47 $ - $ -

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

$ 0.19 $ 2.92 $ 2.38 $ 0.64 $ 6.14 $ - $ 29.20 $ - $ - $ - $ (0.09) $ (0.90) $ (1.35) $ (2.33) $ (0.02) $ (0.23) $ (0.19) $ (0.06) $ (0.50) $ 0.10 $ (2.73) $ - $ -

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

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

Markup Markup Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total 

Packaging 

Cost 

(Component

/ Assembly)

Total Markup 

Cost 

(Component/ 

Assembly)

6 06

7 65

8 70

9 75

10 80

11 85

12 90

13 95

14 99

0 0

0 0

0 0

0 0

0 0

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 2.19 $ 1.46 $ 1.27 $ 4.93 $ 0.04 $ 0.60 $ 0.49 $ 0.14 $ 1.27 $ 0.05 $ 6.25 $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 1.21 $ 0.40 $ 0.29 $ 1.89 $ 0.01 $ 0.21 $ 0.14 $ 0.02 $ 0.37 $ 0.02 $ 2.28 $ - $ -

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

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

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

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

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

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

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

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

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

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

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

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

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

Markup Markup Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total 

Packaging 

Cost 

(Component

/ Assembly)

Total Markup 

Cost 

(Component/ 

Assembly)

$ 0.19 $ 2.92 $ 2.38 $ 0.64 $ 6.14 $ - $ 29.20 $ - $ - $ - $ 28.03 $ 4.06 $ 4.70 $ 36.78 $ 0.21 $ 2.93 $ 2.55 $ 0.91 $ 6.60 $ 0.24 $ 43.62 $ - $ -

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

021200 Transmission Cooling Subsystem

1 00

2 01

3 02

4 04

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 06

7 65

8 70

9 75

10 80

11 85

12 90

13 95

14 99

0 0

0 0

0 0

0 0

0 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

Investment(X1

000)

$ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
0

021200 Transmission Cooling Subsystem

1 00

A H Trans Vehicle Mounting Hardware 02 # 00 - N0502- 01

02 # 00 - N0502- **

2 01

A H Aux Pump Heater Circ Pump Asm 02 # 01 - N0502- 01

02 # 01 - N0502- **

Name/Description Part Number

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component

Assembly of Cooling Subsystem

Water Pumps

Technology Level: Parallel HEV Technology

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

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

02 # 01 - N0502- **

3 02

02 # 02 - N0502- 01

02 # 02 - N0502- **

4 04

A H - Cooler Asm Trans DC DC Mod C 02 # 04 - N0502- 01

02 # 04 - N0502- **

5 05

02 # 05 - N0502- 01

02 # 05 - N0502- **

6 06

A H Bottle Asm, Trans Coolant A 02 # 06 - N0502- 01

02 # 06 - N0502- **

7 65

02 # 65 - N0502- 01

02 # 65 - N0502- **

9 70

A H - Trans Cooler Line Asm D 02 # 70 - N0502- 01

02 # 70 - N0502- **

Expansion Tanks

Heat Exchangers

Pressure Regulators

Thermostat Housings

Pipes, Hoses, Ducting

Adapters
10 75

02 # 75 - N0502- 01

02 # 75 - N0502- **

11 80

02 # 80 - N0502- 01

02 # 80 - N0502- **

12 85

02 # 85 - N0502- 01

02 # 85 - N0502- **

13 90

02 # 90 - N0502- 01

02 # 90 - N0502- **

14 95

02 # 95 - N0502- 01

02 # 95 - N0502- **

15 99

02 # 99 - N0502- 01

02 # 99 - N0502- **

NOTES:

1.

Tools

Sealing Elements

Brackets

Boltings

Bearings Elements Misc

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing diffe

Miscellaneous

1.

the competing technology
Material Labor Burden

$ - $ - $ -

$ 0.36 $ - $ -

1 Full 1 $ 0.36 $ - $ -

$ 24.35 $ 3.09 $ 4.49

1 Full 1 $ 24.35 $ 3.09 $ 4.49

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Q

T

Y/ Subsyste

m

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Notes

Manufacturing 

6 Passengers

logy Package, 02=Vehicle Class

$ - $ - $ -

$ 4.80 $ 8.09 $ 7.84

1 Full 1 $ 4.80 $ 8.09 $ 7.84

$ - $ - $ -

$ 2.19 $ 1.46 $ 1.27

1 Full 1 $ 2.19 $ 1.46 $ 1.27

$ - $ - $ -

$ 1.21 $ 0.40 $ 0.29

1 Full 1 $ 1.21 $ 0.40 $ 0.29
$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ 32.91 $ 13.04 $ 13.89

/or manufacturing differentials are accounted for in the quote sheet of 
End Item 

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

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

$ 0.36 $ - $ - $ - $ - $ - $ - $ 0.36

$ 0.36 $ - $ - $ - $ - $ - $ - $ 0.36

$ 31.93 $ 0.17 $ 2.36 $ 2.11 $ 0.81 $ 5.46 $ 0.08 $ 37.47

$ 31.93 $ 0.17 $ 2.36 $ 2.11 $ 0.81 $ 5.46 $ 0.08 $ 37.47

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY PACKAGE COST INFORMATION

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly

Cost Impact to 

OEM

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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

$ - $ - $ - $ -

$ 20.73 $ 0.18 $ 2.69 $ 2.19 $ 0.58 $ 5.63 $ 0.10 $ 26.46

$ 20.73 $ 0.18 $ 2.69 $ 2.19 $ 0.58 $ 5.63 $ 0.10 $ 26.46

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

$ 4.93 $ 0.04 $ 0.60 $ 0.49 $ 0.14 $ 1.27 $ 0.05 $ 6.25

$ 4.93 $ 0.04 $ 0.60 $ 0.49 $ 0.14 $ 1.27 $ 0.05 $ 6.25

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

$ 1.89 $ 0.01 $ 0.21 $ 0.14 $ 0.02 $ 0.37 $ 0.02 $ 2.28

$ 1.89 $ 0.01 $ 0.21 $ 0.14 $ 0.02 $ 0.37 $ 0.02 $ 2.28
$ - $ - $ - $ - $ - $ - $ - $ -

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

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

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

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

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

$ 59.84 $ 0.40 $ 5.85 $ 4.93 $ 1.55 $ 12.74 $ 0.24 $ 72.82
$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

Investment

(X1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

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

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Vehicle Mounting Hardware Part Number: 021200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 7 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Vehicle Mounting Hardware Part Number: 021200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Vehicle Mounting Hardware Part Number: 021200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 H Bolt Trans Coolant Bottle 011404-N0502-02 1 S $0.00 $0.06 $0.00 $0.06 $0.06

3 H Nut Trans Coolant Bottle 011404-N0502-03 1 S $0.00 $0.06 $0.00 $0.06 $0.06

4 H Bolt, Trans Coolant Pump 011404-N0502-04 2 S $0.00 $0.06 $0.00 $0.12 $0.12

5 H Bolt, Trans Cooler to FEM 011404-N0502-05 1 S $0.00 $0.06 $0.00 $0.06 $0.06

4 H Bolt, Trans Cooler to FEM 011404-N0502-06 1 S $0.00 $0.06 $0.00 $0.06 $0.06

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.36

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $0.36

T1 or OEM Total Manufacturing Cost: $0.36 $0.00 $0.00 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 $0.36

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $0.00

Base Cost Impact to Vehicle: $0.36 $0.00 $0.00 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 $0.36 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must a

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.36

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Vehicle Mounting Hardware Part Number: 021200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.1 1.0

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 7.0

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

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

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

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

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

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

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

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

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

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

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

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

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

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Bolt Trans Coolant Bottle 011404-N0502-02

H Nut Trans Coolant Bottle 011404-N0502-03

H Bolt, Trans Coolant Pump 011404-N0502-04

H Bolt, Trans Cooler to FEM 011404-N0502-05

H Bolt, Trans Cooler to FEM 011404-N0502-06

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00

$0.06

$0.06

$0.12

$0.06

$0.06

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00

$0.36

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Bolt Trans Coolant Bottle 011404-N0502-02

H Nut Trans Coolant Bottle 011404-N0502-03

H Bolt, Trans Coolant Pump 011404-N0502-04

H Bolt, Trans Cooler to FEM 011404-N0502-05

H Bolt, Trans Cooler to FEM 011404-N0502-06

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Bottle Asm, Trans Coolant A Part Number: 021306-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.711 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 H Isolation Ring, Mount, Coolant Pump 021306-N0502-19 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS 1091 1 1 1 0.049 $1.32 $41.48 $16.39 $16.39 $0.06 $0.04 $0.02 $0.12 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.13 $0.13 $0.06

5 H Clamp, Mount, Coolant Pump 021306-N0502-20 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 3000 1 1 1 0.066 $1.74 $41.48 $16.39 $16.39 $0.11 $0.01 $0.01 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $0.11

6 H Bracket, Mount, Coolant Pump 021306-N0502-21 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 277 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.07 $0.05 $0.12 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.14 $0.14 $0.00

7 021306-N0502-21A 1 Paint T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 152 0.5 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.13 $0.30 $0.42 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.47 $0.47 $0.00

8 021306-N0502-21B 1 Wash T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.48 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.00

9 021306-N0502-21C 1 Stamp T2/T3 Stamp/Form, MSMC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.303 $0.48 $42.73 $15.50 $15.50 $0.15 $0.00 $0.00 $0.15 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.17 $0.15

10 H Clamp On Christmas Tree Clip 021306-N0502-22 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 3273 1 1 1 0.026 $1.74 $41.48 $16.39 $16.39 $0.05 $0.01 $0.01 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.07 $0.07 $0.05

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Bottle Asm, Trans Coolant A Part Number: 021306-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

11 H Coolant Line, Pump to E Motor 021306-N0502-23 1 Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS 522 1 1 1 0.340 $1.32 $56.05 $35.94 $35.94 $0.45 $0.11 $0.07 $0.63 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.69 $0.69 $0.45

12 H Coolant Line, DC-DC to Pump 021306-N0502-24 1 Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS 225 1 1 1 0.502 $1.32 $56.05 $35.94 $35.94 $0.66 $0.25 $0.16 $1.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.18 $1.18 $0.66

13 H Coolant Line Asm, DC-DC to Pump 021306-N0502-25 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 174 1.5 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.33 $0.26 $0.59 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.65 $0.65 $0.00

14 H Coolant Line Asm, Pump to E motor 021306-N0502-26 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 138 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.14 $0.11 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.27 $0.27 $0.00

15 H Trans Coolant Pump w/Mount 021306-N0502-27 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 148 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.13 $0.10 $0.23 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26 $0.26 $0.00

16 H Trans Coolant Pump Sub Asm. 021306-N0502-28 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 189 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.20 $0.16 $0.36 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.40 $0.40 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Bottle Asm, Trans Coolant A Part Number: 021306-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 H Sheath, (15/16"), Bottle to Trans Hose 021306-N0502-15 1 S $0.00 $0.18 $0.00 $0.18 $0.18

4 H Hose Clamp, Medium (24mm) 021306-N0502-16 1 S $0.00 $0.22 $0.00 $0.22 $0.22

5 H Hose Clamp, Medium (22mm) 021306-N0502-17 1 S $0.00 $0.21 $0.00 $0.21 $0.21

6 H Label, Trans Cooler Bottle 021306-N0502-18 1 S $0.00 $0.10 $0.00 $0.10 $0.10

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 6 H Label, Trans Cooler Bottle 021306-N0502-18 1 S $0.00 $0.10 $0.00 $0.10 $0.10

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$2.19

Material Labor Burden TMC Scrap SG&A Profit ED&T Total $5.37

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

Mark-up $5.37

T1 or OEM Total Manufacturing Cost: $2.19 $1.46 $1.27 $4.93 $0.01 $0.25 $0.17 $0.00 $0.44 $5.37

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.35 $0.32 $0.13 $0.83

Base Cost Impact to Vehicle: $2.19 $1.46 $1.27 $4.93 $0.04 $0.60 $0.49 $0.14 $1.27 $6.20 $0 $0

Packaging Cost: $0.05

Net Cost Impact to Vehicle: $6.25

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Bottle Asm, Trans Coolant A Part Number: 021306-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.1 1.0

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

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

H Isolation Ring, Mount, Coolant Pump 021306-N0502-19

H Clamp, Mount, Coolant Pump 021306-N0502-20

H Bracket, Mount, Coolant Pump 021306-N0502-21

021306-N0502-21A

021306-N0502-21B

021306-N0502-21C

H Clamp On Christmas Tree Clip 021306-N0502-22

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

$0.04 $0.02 $0.12 $0.00 $0.01 $0.00 $0.00 $0.01 55-150 ton , 12 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 3.3 1 12 39.6 1.0 1.0

$0.01 $0.01 $0.13 $0.00 $0.01 $0.01 $0.00 $0.01 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.2 1 14 16.8 1.0 1.0

$0.07 $0.05 $0.12 $0.00 $0.01 $0.00 $0.00 $0.01 Peal offf backing and press foam pad to bracket 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 3 1 13 1.00 1.0

$0.13 $0.30 $0.42 $0.00 $0.03 $0.02 $0.00 $0.04 Dipped/air dryed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 71 1 1 71 1.0 3.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.00 $0.00 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 0-60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.01 $0.01 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.1 1 14 15.4 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Coolant Line, Pump to E Motor 021306-N0502-23

H Coolant Line, DC-DC to Pump 021306-N0502-24

H Coolant Line Asm, DC-DC to Pump 021306-N0502-25

H Coolant Line Asm, Pump to E motor 021306-N0502-26

H Trans Coolant Pump w/Mount 021306-N0502-27

H Trans Coolant Pump Sub Asm. 021306-N0502-28

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.11 $0.07 $0.63 $0.00 $0.04 $0.03 $0.00 $0.06 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 6.9 1 1 6.9 1.0 1.0

$0.25 $0.16 $1.07 $0.00 $0.06 $0.04 $0.00 $0.11 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 1 16 1.0 1.0

$0.33 $0.26 $0.59 $0.00 $0.04 $0.02 $0.00 $0.06 Slip on sheath to coolant line and add clamps. Attach strap on hose clip and zip tie - trim to length. Add 

clamp on xmas tree to asm. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 62 4 1 62 1.0 3.0

$0.14 $0.11 $0.25 $0.00 $0.01 $0.01 $0.00 $0.03 Attach clips to hose 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 2 1 26 1.0 1.0

$0.13 $0.10 $0.23 $0.00 $0.01 $0.01 $0.00 $0.02 Place isolation ring onto trans coolant pump. Position clamp and bracket and snap onto trans coolant 

pump 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24.4 3 1 24.4 1.0 1.0

$0.20 $0.16 $0.36 $0.00 $0.02 $0.01 $0.00 $0.04 Clamp coolant lines to trans coolant pump 5 2 10 100 47 4700 96 37.60 85% 113 31.96 38 2 1 38 1.0 2.0

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

H Sheath, (15/16"), Bottle to Trans Hose 021306-N0502-15

H Hose Clamp, Medium (24mm) 021306-N0502-16

H Hose Clamp, Medium (22mm) 021306-N0502-17

H Label, Trans Cooler Bottle 021306-N0502-18

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

$0.00

$0.00

$0.18

$0.22

$0.21

H Label, Trans Cooler Bottle 021306-N0502-18 $0.10

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.46 $1.27 $4.93 $0.01 $0.25 $0.17 $0.00 $0.44

$5.37

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H Isolation Ring, Mount, Coolant Pump 021306-N0502-19

H Clamp, Mount, Coolant Pump 021306-N0502-20

H Bracket, Mount, Coolant Pump 021306-N0502-21

021306-N0502-21A

021306-N0502-21B

021306-N0502-21C

H Clamp On Christmas Tree Clip 021306-N0502-22

#DIV/0! #DIV/0! -

1091 3.30 1.00

3000 1.20 1.00

277 13.00 0.50

152 23.67 0.50

277 13.00 0.25

5143 0.70 0.50

3273 1.10 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Coolant Line, Pump to E Motor 021306-N0502-23

H Coolant Line, DC-DC to Pump 021306-N0502-24

H Coolant Line Asm, DC-DC to Pump 021306-N0502-25

H Coolant Line Asm, Pump to E motor 021306-N0502-26

H Trans Coolant Pump w/Mount 021306-N0502-27

H Trans Coolant Pump Sub Asm. 021306-N0502-28

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

522 6.90 1.00

225 16.00 1.00

174 20.67 1.50

138 26.00 0.50

148 24.40 0.50

189 19.00 1.00

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

H Sheath, (15/16"), Bottle to Trans Hose 021306-N0502-15

H Hose Clamp, Medium (24mm) 021306-N0502-16

H Hose Clamp, Medium (22mm) 021306-N0502-17

H Label, Trans Cooler Bottle 021306-N0502-18

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H Label, Trans Cooler Bottle 021306-N0502-18

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Aux Pump Heater Circ Pump Asm Part Number: 021301-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 H Isolation Ring, Mount, Coolant Pump 021301-N0502-19 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS 1091 1 1 1 0.049 $1.32 $41.48 $16.39 $16.39 $0.06 $0.04 $0.02 $0.12 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.13 $0.13 $0.06

3 H Clamp, Mount, Coolant Pump 021301-N0502-20 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS Inject. Mold, SS 3000 1 1 1 0.066 $1.74 $41.48 $16.39 $16.39 $0.11 $0.01 $0.01 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $0.11

4 H Bracket, Mount, Coolant Pump 021301-N0502-21 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 277 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.07 $0.05 $0.12 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.14 $0.14 $0.00

5 021301-N0502-21A 1 Paint T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 152 0.5 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.13 $0.30 $0.42 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.47 $0.47 $0.00

6 021301-N0502-21B 1 Wash T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.48 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.00

7 021301-N0502-21C 1 Stamp T2/T3 Stamp/Form, MSMC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.303 $0.48 $42.73 $15.50 $15.50 $0.15 $0.00 $0.00 $0.15 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.17 $0.15

8 H Clamp On Christmas Tree Clip 021301-N0502-22 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 3273 1 1 1 0.026 $1.74 $41.48 $16.39 $16.39 $0.05 $0.01 $0.01 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.07 $0.07 $0.05

9 H Coolant Line, Pump to E Motor 021301-N0502-23 1 Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS 522 1 1 1 0.340 $1.32 $56.05 $35.94 $35.94 $0.45 $0.11 $0.07 $0.63 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.69 $0.69 $0.45

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Aux Pump Heater Circ Pump Asm Part Number: 021301-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

10 H Coolant Line, DC-DC to Pump 021301-N0502-24 1 Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS 225 1 1 1 0.502 $1.32 $56.05 $35.94 $35.94 $0.66 $0.25 $0.16 $1.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.18 $1.18 $0.66

11 H Coolant Line Asm, DC-DC to Pump 021301-N0502-25 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 174 1.5 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.33 $0.26 $0.59 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.65 $0.65 $0.00

12 H Coolant Line Asm, Pump to E motor 021301-N0502-26 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 138 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.14 $0.11 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.27 $0.27 $0.00

13 H Trans Coolant Pump w/Mount 021301-N0502-27 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 148 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.13 $0.10 $0.23 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26 $0.26 $0.00

14 H Trans Coolant Pump Sub Asm. 021301-N0502-28 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 189 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.20 $0.16 $0.36 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.40 $0.40 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 1A H Aux Heater Cir Pump 021301-N0502-02 1 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A $20.85 $1.63 $3.22 $25.70 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $25.70 $25.70 $20.85

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 H Foam Pad, Self Stick, Pump Bracket 021301-N0502-29 1 S $0.00 $0.01 $0.00 $0.01 $0.01

3 H Hose Clamp, Medium (27mm) 021301-N0502-30 2 S $0.00 $0.23 $0.00 $0.46 $0.46

4 H Sheath, (15/16"), Pump to Dc-Dc Module 021301-N0502-31 1 S $0.00 $1.19 $0.00 $1.19 $1.19

5 H Hose Clamp, Medium (27mm) 021301-N0502-32 1 S $0.00 $0.23 $0.00 $0.23 $0.23

4 H Strap On Hose Clip (#7) 021301-N0502-33 1 S $0.00 $0.04 $0.00 $0.04 $0.04

7 H Clamp On Christmas Tree Clip 021301-N0502-34 1 S $0.00 $0.08 $0.00 $0.08 $0.08

8 H Zip Tie 021301-N0502-35 1 S $0.00 $0.01 $0.00 $0.01 $0.01

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

Imported detailed cost analysis from Mini Cooper Turbo afterrun pump - increased material pricing by x1.5 to account for 

larger pump size.

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier for Subassembly.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Aux Pump Heater Circ Pump Asm Part Number: 021301-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$24.35

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $32.37

T1 or OEM Total Manufacturing Cost: $24.35 $3.09 $4.49 $31.93 $0.01 $0.25 $0.17 $0.00 $0.44 $32.37

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.16 $2.10 $1.94 $0.81 $5.02

Base Cost Impact to Vehicle: $24.35 $3.09 $4.49 $31.93 $0.17 $2.36 $2.11 $0.81 $5.46 $37.39 $0 $0

Packaging Cost: $0.08

Net Cost Impact to Vehicle: $37.47

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type: Specialized Racking/Containers

(Estimate $0.12/part)

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Aux Pump Heater Circ Pump Asm Part Number: 021301-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.1 1.0

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Purchase Part - High Impact Item (Full Cost Mapping)

H Isolation Ring, Mount, Coolant Pump 021301-N0502-19

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.04 $0.02 $0.12 $0.00 $0.01 $0.00 $0.00 $0.01 55-150 ton , 12 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 3.3 1 12 39.6 1.0 1.0

H Clamp, Mount, Coolant Pump 021301-N0502-20

H Bracket, Mount, Coolant Pump 021301-N0502-21

021301-N0502-21A

021301-N0502-21B

021301-N0502-21C

H Clamp On Christmas Tree Clip 021301-N0502-22

H Coolant Line, Pump to E Motor 021301-N0502-23

$0.01 $0.01 $0.13 $0.00 $0.01 $0.01 $0.00 $0.01 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.2 1 14 16.8 1.0 1.0

$0.07 $0.05 $0.12 $0.00 $0.01 $0.00 $0.00 $0.01 Peal offf backing and press foam pad to bracket 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 3 1 13 1.00 1.0

$0.13 $0.30 $0.42 $0.00 $0.03 $0.02 $0.00 $0.04 Dipped/air dryed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 71 1 1 71 1.0 3.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.00 $0.00 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 0-60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.01 $0.01 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.1 1 14 15.4 1.0 1.0

$0.11 $0.07 $0.63 $0.00 $0.04 $0.03 $0.00 $0.06 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 6.9 1 1 6.9 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Coolant Line, DC-DC to Pump 021301-N0502-24

H Coolant Line Asm, DC-DC to Pump 021301-N0502-25

H Coolant Line Asm, Pump to E motor 021301-N0502-26

H Trans Coolant Pump w/Mount 021301-N0502-27

H Trans Coolant Pump Sub Asm. 021301-N0502-28

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.25 $0.16 $1.07 $0.00 $0.06 $0.04 $0.00 $0.11 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 1 16 1.0 1.0

$0.33 $0.26 $0.59 $0.00 $0.04 $0.02 $0.00 $0.06 Slip on sheath to coolant line and add clamps. Attach strap on hose clip and zip tie - trim to length. Add 

clamp on xmas tree to asm. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 62 4 1 62 1.0 3.0

$0.14 $0.11 $0.25 $0.00 $0.01 $0.01 $0.00 $0.03 Attach clips to hose 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 2 1 26 1.0 1.0

$0.13 $0.10 $0.23 $0.00 $0.01 $0.01 $0.00 $0.02 Place isolation ring onto trans coolant pump. Position clamp and bracket and snap onto trans coolant 

pump 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24.4 3 1 24.4 1.0 1.0

$0.20 $0.16 $0.36 $0.00 $0.02 $0.01 $0.00 $0.04 Clamp coolant lines to trans coolant pump 5 2 10 100 47 4700 96 37.60 85% 113 31.96 38 2 1 38 1.0 2.0

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

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

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1A H Aux Heater Cir Pump 021301-N0502-02

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

H Foam Pad, Self Stick, Pump Bracket 021301-N0502-29

H Hose Clamp, Medium (27mm) 021301-N0502-30

H Sheath, (15/16"), Pump to Dc-Dc Module 021301-N0502-31

H Hose Clamp, Medium (27mm) 021301-N0502-32

H Strap On Hose Clip (#7) 021301-N0502-33

H Clamp On Christmas Tree Clip 021301-N0502-34

H Zip Tie 021301-N0502-35

5 2 10 100 47 4700

$1.63 $3.22 $25.70 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - - - 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

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

$0.00

$0.01

$0.46

$1.19

$0.23

$0.04

$0.08

$0.01

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$3.09 $4.49 $31.93 $0.01 $0.25 $0.17 $0.00 $0.44

$32.37

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

H Isolation Ring, Mount, Coolant Pump 021301-N0502-19

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

1091 3.30 1.00

H Clamp, Mount, Coolant Pump 021301-N0502-20

H Bracket, Mount, Coolant Pump 021301-N0502-21

021301-N0502-21A

021301-N0502-21B

021301-N0502-21C

H Clamp On Christmas Tree Clip 021301-N0502-22

H Coolant Line, Pump to E Motor 021301-N0502-23

3000 1.20 1.00

277 13.00 0.50

152 23.67 0.50

277 13.00 0.25

5143 0.70 0.50

3273 1.10 1.00

522 6.90 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Coolant Line, DC-DC to Pump 021301-N0502-24

H Coolant Line Asm, DC-DC to Pump 021301-N0502-25

H Coolant Line Asm, Pump to E motor 021301-N0502-26

H Trans Coolant Pump w/Mount 021301-N0502-27

H Trans Coolant Pump Sub Asm. 021301-N0502-28

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

225 16.00 1.00

174 20.67 1.50

138 26.00 0.50

148 24.40 0.50

189 19.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1A H Aux Heater Cir Pump 021301-N0502-02

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

H Foam Pad, Self Stick, Pump Bracket 021301-N0502-29

H Hose Clamp, Medium (27mm) 021301-N0502-30

H Sheath, (15/16"), Pump to Dc-Dc Module 021301-N0502-31

H Hose Clamp, Medium (27mm) 021301-N0502-32

H Strap On Hose Clip (#7) 021301-N0502-33

H Clamp On Christmas Tree Clip 021301-N0502-34

H Zip Tie 021301-N0502-35

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H - Cooler Asm Trans DC DC Mod C Part Number: 021104-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 H Hose, Trans Cooler H Hose, Trans Cooler 021304-N0502-37 021304-N0502-37 1 Cut/Extrude Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Thermoset-SBR Extruding/Drawing Operator Extruding/Drawing Operator Extrusion Molding, NR, SS Extrusion Molding, NR, SS 720 1 1 1 0.2270 $1.32 $56.05 $35.94 $35.94 $0.30 $0.08 $0.05 $0.43 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.47 $0.47 $0.30

3

H Rubber Tube, 17 mm Diam

021304-N0502-38 1 Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-EPDM Extruding/Drawing Operator Extrusion Molding, NR, SS 6000 1 1 1 0.0080 $1.83 $56.05 $35.94 $35.94 $0.01 $0.01 $0.01 $0.03 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.03 $0.03 $0.01

4 H Pipe, Tube Asm, Trans Cooler Asm. 021304-N0502-39 1 Bend/Flare ends T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 113 0.5 1 1 0.1026 $0.84 $42.73 $50.00 $50.00 $0.09 $0.19 $0.44 $0.72 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.79 $0.79 $0.09

5 H Fitting, Tube Asm, 021304-N0502-40 1 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

6 021304-N0502-40A 1 Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC 159 1.5 3 1 0.000 $0.00 $36.98 $30.38 $91.14 $0.00 $0.35 $0.57 $0.92 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.02 $1.02 $0.00

7 021304-N0502-40B 1 Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Aluminum-4032, Bar Extruding/Drawing Operator Extrusion Molding, NR, SS 554 1 1 1 0.0739 $1.44 $56.05 $35.94 $35.94 $0.11 $0.10 $0.06 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.30 $0.30 $0.11

8 H Fluid Pipe Fitting Exchanger Asm. 021304-N0502-41 1 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

9 021304-N0502-41A 1 Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC 309 1.5 3 1 0.000 $0.00 $36.98 $30.38 $91.14 $0.00 $0.18 $0.30 $0.48 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.52 $0.52 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H - Cooler Asm Trans DC DC Mod C Part Number: 021104-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

10 021304-N0502-41B 1 Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Aluminum-4032, Bar Extruding/Drawing Operator Extrusion Molding, NR, SS 900 1 1 1 0.0594 $1.44 $56.05 $35.94 $35.94 $0.09 $0.06 $0.04 $0.19 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.21 $0.21 $0.09

11 H Locator Bracket, Exchanger 021304-N0502-42 1 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

12 021304-N0502-42A 1 T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC 900 1 1 1 0.0299 $0.84 $42.73 $25.00 $25.00 $0.03 $0.05 $0.03 $0.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.11 $0.11 $0.03

13 H RH Mounting Bracket, Exchanger 021304-N0502-43 1 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

14 021304-N0502-43A 1 Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC 831 1.5 3 1 0.000 $0.00 $36.98 $30.38 $91.14 $0.00 $0.07 $0.11 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.00

15 021304-N0502-43B 1 T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC 900 1 1 1 0.0293 $0.84 $42.73 $25.00 $25.00 $0.02 $0.05 $0.03 $0.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.11 $0.11 $0.02

16 H Locator Bracket, Exchanger 021304-N0502-44 1 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

17 021304-N0502-44A 1 T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC 900 1 1 1 0.0299 $0.84 $42.73 $25.00 $25.00 $0.03 $0.05 $0.03 $0.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.11 $0.11 $0.03

18 H LH Mounting Bracket, Exchanger 021304-N0502-45 1 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

19 021304-N0502-45A 1 Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC 831 1.5 3 1 0.000 $0.00 $36.98 $30.38 $91.14 $0.00 $0.07 $0.11 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.00

20 021304-N0502-45B 1 T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC 900 1 1 1 0.0288 $0.84 $42.73 $25.00 $25.00 $0.02 $0.05 $0.03 $0.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.11 $0.11 $0.02

21 H Return Tube, Exchanger Asm. 021304-N0502-46 1 Bend/Flare ends T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 100 0.5 1 1 0.0361 $0.84 $42.73 $50.00 $50.00 $0.03 $0.21 $0.50 $0.74 0.30% 6.00% 4.00% 0.00% 10.30% $0.08 $0.82 $0.82 $0.03

22 H Tank Endcap, Exchanger 021304-N0502-47 2 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.011 $0.84 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.02 0.50% 6.50% 6.00% 1.00% 14.00% $0.00 $0.02 $0.04 $0.02

23 H Tank Endcap, Exchanger 021304-N0502-48 2 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.011 $0.84 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.02 0.50% 6.50% 6.00% 1.00% 14.00% $0.00 $0.02 $0.04 $0.02

24 H LH Outboard Tank, Exchanger 021304-N0502-49 1 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.069 $0.84 $42.73 $15.50 $15.50 $0.06 $0.00 $0.00 $0.07 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.07 $0.07 $0.06

25 H RH Outboard Tank, Exchanger 021304-N0502-50 1 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.069 $0.84 $42.73 $15.50 $15.50 $0.06 $0.00 $0.00 $0.07 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.07 $0.07 $0.06

26 H Inboard Tank, Exchanger 021304-N0502-51 1 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 2000 0.5 1 1 0.069 $0.84 $42.73 $42.91 $42.91 $0.06 $0.01 $0.02 $0.09 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.10 $0.10 $0.06

27 H Inboard Tank, Exchanger 021304-N0502-52 1 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 2000 0.5 1 1 0.069 $0.84 $42.73 $42.91 $42.91 $0.06 $0.01 $0.02 $0.09 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.10 $0.10 $0.06

28 H Tube Exchanger Asm 021304-N0502-53 17 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $4.99 $0.00

29 021304-N0502-54 17 T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3003, Coil A Cut/Punch/Forming Operator CNC Form, SS, LC 3600 0.5 1 1 0.1075 $1.41 $42.73 $25.00 $25.00 $0.15 $0.01 $0.01 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $3.08 $2.58

30 H Fin Exchanger Asm 021304-N0502-55 16 Roll Form T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 4500 0.5 1 1 0.0346 $0.84 $42.73 $42.91 $42.91 $0.03 $0.00 $0.01 $0.04 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.05 $0.79 $0.47

31 H Hose Asm, Trans Cooler 021304-N0502-56 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 144 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.13 $0.10 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26 $0.26 $0.00

32 H Tube Asm, Trans Cooler Asm. 021304-N0502-57 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 189 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.20 $0.16 $0.36 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.40 $0.40 $0.00

33 H Tube & Hose Asm, Trans Cooler Asm. 021304-N0502-58 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 121 1.5 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.48 $0.37 $0.85 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $0.93 $0.93 $0.00

34 H RH Outboard Tank, Exchanger 021304-N0502-59 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 158 1.5 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.37 $0.19 $0.56 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.61 $0.61 $0.00

35 H LH Outboard Tank, Exchanger 021304-N0502-60 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 134 1.5 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.43 $0.22 $0.65 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.72 $0.72 $0.00

36 H Cooler Core Asm, Exchanger 021304-N0502-61 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 118 2.5 5 1 0.000 $0.00 $38.55 $15.00 $75.00 $0.00 $0.82 $0.64 $1.46 0.30% 6.00% 4.00% 0.00% 10.30% $0.15 $1.61 $1.61 $0.00

37 H Cooler Asm, Trans & DC-DC Mod H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62 021304-N0502-62 1 Assemble Assemble T2/T3 Mech. Assembly, SSLC T2/T3 Mech. Assembly, SSLC Not Applicable Not Applicable General Assembly General Assembly Mech Assembly, LC, Base Mech Assembly, LC, Base 144 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.13 $0.10 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26 $0.26 $0.00

38 H Exchanger Asm, Trans Cooler Asm. 021304-N0502-62A 1 Paint T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 257 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.04 $0.06 $0.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.11 $0.11 $0.00

39 021304-N0502-62B 1 Oven Braze T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator T5-Al380, SMS 124 1.5 1 1 0.000 $0.00 $47.72 $10.17 $10.17 $0.00 $0.58 $0.08 $0.66 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.73 $0.73 $0.00

40 021304-N0502-62C 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LC 257 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.04 $0.04 $0.08 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.09 $0.00

41 021304-N0502-62 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 212 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.18 $0.07 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.28 $0.28 $0.00

42 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

43 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

44 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

45 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H - Cooler Asm Trans DC DC Mod C Part Number: 021104-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

46 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 H Oetiker Clamp, Medium (26.5mm) 021304-N0502-63 1 S $0.00 $0.25 $0.00 $0.25 $0.25

7 H Hose Clamp, Medium (27mm) 021304-N0502-64 1 S $0.00 $0.23 $0.00 $0.23 $0.23

8 H O-Ring, 18.5 x 2.5 mm 021304-N0502-65 1 S $0.00 $0.06 $0.00 $0.06 $0.06

9 H Heat Shrink Fabric Tube, 21 mmm Diam 021304-N0502-66 1 S $0.00 $0.07 $0.00 $0.07 $0.07

10 H Bolt, Line Asm to Exchanger 021304-N0502-67 1 S $0.00 $0.06 $0.00 $0.06 $0.06

11 H Label, Cooler Asm. 021304-N0502-68 1 S $0.00 $0.10 $0.00 $0.10 $0.10

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H - Cooler Asm Trans DC DC Mod C Part Number: 021104-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$4.80

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $22.83

T1 or OEM Total Manufacturing Cost: $4.80 $8.09 $7.84 $20.73 $0.06 $1.20 $0.82 $0.01 $2.10 $22.83

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.11 $1.48 $1.37 $0.57 $3.54

Base Cost Impact to Vehicle: $4.80 $8.09 $7.84 $20.73 $0.18 $2.69 $2.19 $0.58 $5.63 $26.36 $0 $0

Packaging Cost: $0.10

Net Cost Impact to Vehicle: $26.46

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H - Cooler Asm Trans DC DC Mod C Part Number: 021104-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.1 1.0

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Purchase Part - High Impact Item (Full Cost Mapping)

H Hose, Trans Cooler 021304-N0502-37

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

H Hose, Trans Cooler 021304-N0502-37 $0.08 $0.05 $0.43 $0.00 $0.03 $0.02 $0.00 $0.04 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 5 1 1 5 1.0 1.0

H Rubber Tube, 17 mm Diam

021304-N0502-38

H Pipe, Tube Asm, Trans Cooler Asm. 021304-N0502-39

H Fitting, Tube Asm, 021304-N0502-40

021304-N0502-40A

021304-N0502-40B

H Fluid Pipe Fitting Exchanger Asm. 021304-N0502-41

021304-N0502-41A

$0.08 $0.05 $0.43 $0.00 $0.03 $0.02 $0.00 $0.04 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 5 1 1 5 1.0 1.0

$0.01 $0.01 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 1 1 0.6 1.0 1.0

$0.19 $0.44 $0.72 $0.00 $0.04 $0.03 $0.00 $0.07 Tube form and flare, Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 32 1 1 32 1.0 1.0

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Debur 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.35 $0.57 $0.92 $0.00 $0.06 $0.04 $0.00 $0.10 EC-300-ML Horizontal CNC 5 2 10 100 47 4700 96 37.60 85% 113 31.96 68 10 1 68 1.0 3.0

$0.10 $0.06 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Extruded Aluminum 5 2 10 100 47 4700 96 37.60 85% 113 31.96 6.5 1 1 6.5 1.0 1.0

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Debur 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.18 $0.30 $0.48 $0.00 $0.03 $0.02 $0.00 $0.05 EC-300-ML Horizontal CNC 5 2 10 100 47 4700 96 37.60 85% 113 31.96 35 5 1 35 1.0 3.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

021304-N0502-41B

H Locator Bracket, Exchanger 021304-N0502-42

021304-N0502-42A

H RH Mounting Bracket, Exchanger 021304-N0502-43

021304-N0502-43A

021304-N0502-43B

H Locator Bracket, Exchanger 021304-N0502-44

021304-N0502-44A

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.06 $0.04 $0.19 $0.00 $0.01 $0.01 $0.00 $0.02 Extruded Aluminum 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4 1 1 4 1.0 1.0

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Debur 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.05 $0.03 $0.10 $0.00 $0.01 $0.00 $0.00 $0.01 Cut to size - cut off tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4 1 1 4 1.0 1.0

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Debur 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.07 $0.11 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 EC-300-ML Horizontal CNC 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 3.0

$0.05 $0.03 $0.10 $0.00 $0.01 $0.00 $0.00 $0.01 Cut to size 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4 1 1 4 1.0 1.0

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Debur 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.05 $0.03 $0.10 $0.00 $0.01 $0.00 $0.00 $0.01 Extruded Aluminum 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4 1 1 4 1.0 1.0

H LH Mounting Bracket, Exchanger 021304-N0502-45

021304-N0502-45A

021304-N0502-45B

H Return Tube, Exchanger Asm. 021304-N0502-46

H Tank Endcap, Exchanger 021304-N0502-47

H Tank Endcap, Exchanger 021304-N0502-48

H LH Outboard Tank, Exchanger 021304-N0502-49

H RH Outboard Tank, Exchanger 021304-N0502-50

H Inboard Tank, Exchanger 021304-N0502-51

H Inboard Tank, Exchanger 021304-N0502-52

H Tube Exchanger Asm 021304-N0502-53

021304-N0502-54

H Fin Exchanger Asm 021304-N0502-55

H Hose Asm, Trans Cooler 021304-N0502-56

H Tube Asm, Trans Cooler Asm. 021304-N0502-57

H Tube & Hose Asm, Trans Cooler Asm. 021304-N0502-58

H RH Outboard Tank, Exchanger 021304-N0502-59

H LH Outboard Tank, Exchanger 021304-N0502-60

H Cooler Core Asm, Exchanger 021304-N0502-61

H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Cut to size 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.07 $0.11 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 EC-300-ML Horizontal CNC 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 3.0

$0.05 $0.03 $0.10 $0.00 $0.01 $0.00 $0.00 $0.01 Cut to size 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4 1 1 4 1.0 1.0

$0.21 $0.50 $0.74 $0.00 $0.04 $0.03 $0.00 $0.08 Extruded Aluminum 5 2 10 100 47 4700 96 37.60 85% 113 31.96 36 1 1 36 1.0 1.0

$0.01 $0.01 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 0-60 ton progressive die 5 2 10 100 47 4700 191 18.80 85% 225 15.98 0.7 1 1 0.7 1.0 1.0

$0.01 $0.01 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 0-60 ton progressive die 5 2 10 100 47 4700 191 18.80 85% 225 15.98 0.7 1 1 0.7 1.0 1.0

$0.00 $0.00 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01 0-60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.00 $0.00 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01 0-60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.01 $0.02 $0.09 $0.00 $0.01 $0.01 $0.00 $0.01 200-400 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.8 1 1 1.8 1.0 1.0

$0.01 $0.02 $0.09 $0.00 $0.01 $0.01 $0.00 $0.01 200-400 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.8 1 1 1.8 1.0 1.0

$2.19 $2.34 $4.53 $0.01 $0.27 $0.18 $0.00 $0.47 Debur 5 2 10 100 47 4700 1628 2.21 85% 1915 1.88 11 1 1 11 1.0 1.0

$0.10 $0.12 $2.80 $0.01 $0.17 $0.11 $0.00 $0.29 Cut to size 5 2 10 100 47 4700 1628 2.21 85% 1915 1.88 3.0 1 1 1.0 1.0 1.0

$0.08 $0.15 $0.69 $0.00 $0.05 $0.04 $0.01 $0.10 Roll Form 5 2 10 100 47 4700 1532 2.35 85% 1802 2.00 0.8 1 1 0.8 1.0 1.0

$0.13 $0.10 $0.24 $0.00 $0.01 $0.01 $0.00 $0.02 Retract hose clamps and slip on hose. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 2 1 25 1.0 1.0

$0.20 $0.16 $0.36 $0.00 $0.02 $0.01 $0.00 $0.04 Press firtting onto pipe 5 2 10 100 47 4700 96 37.60 85% 113 31.96 38 2 1 38 1.0 2.0

$0.48 $0.37 $0.85 $0.00 $0.05 $0.03 $0.00 $0.09 Press hose on tube. Crimp Slide on rubber tube and heat shink sleeve. Slip on O-ring. Crimp Oetiker 

clamp. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 89 5 1 89 1.0 3.0

$0.37 $0.19 $0.56 $0.00 $0.03 $0.02 $0.00 $0.06 Peen end caps onto outboard tank 5 2 10 100 47 4700 96 37.60 85% 113 31.96 46 1 1 46 1.0 2.0

$0.43 $0.22 $0.65 $0.00 $0.04 $0.03 $0.00 $0.07 Peen end caps onto outboard tank and attach return pipe 5 2 10 100 47 4700 96 37.60 85% 113 31.96 54 1 1 54 1.0 2.0

$0.82 $0.64 $1.46 $0.00 $0.09 $0.06 $0.00 $0.15 Stack 17 tubes and 16 fins 5 2 10 100 47 4700 96 37.60 85% 113 31.96 153 1 1 153 1.0 5.0

H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62 $0.13 $0.10 $0.24 $0.00 $0.01 $0.01 $0.00 $0.02 Bolt tube & hose asm trans cooler to exchange asm trans cooler. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 25 1.0 1.0

H Exchanger Asm, Trans Cooler Asm. 021304-N0502-62A

021304-N0502-62B

021304-N0502-62C

021304-N0502-62

$0.13 $0.10 $0.24 $0.00 $0.01 $0.01 $0.00 $0.02 Bolt tube & hose asm trans cooler to exchange asm trans cooler. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 25 1.0 1.0

$0.04 $0.06 $0.10 $0.00 $0.01 $0.00 $0.00 $0.01 Spray Paint 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 1 14 1.0 1.0

$0.58 $0.08 $0.66 $0.00 $0.04 $0.03 $0.00 $0.07 Oven Braze 5 2 10 100 47 4700 96 37.60 85% 113 31.96 29 1 1 29 1.0 1.0

$0.04 $0.04 $0.08 $0.00 $0.00 $0.00 $0.00 $0.01

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 1 14 1.0 1.0

$0.18 $0.07 $0.25 $0.00 $0.02 $0.01 $0.00 $0.03 Add label 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 1 17 1.0 1.0

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00

$0.00

$0.00

H Oetiker Clamp, Medium (26.5mm) 021304-N0502-63

H Hose Clamp, Medium (27mm) 021304-N0502-64

H O-Ring, 18.5 x 2.5 mm 021304-N0502-65

H Heat Shrink Fabric Tube, 21 mmm Diam 021304-N0502-66

H Bolt, Line Asm to Exchanger 021304-N0502-67

H Label, Cooler Asm. 021304-N0502-68

$0.00

$0.00

$0.00

$0.25

$0.23

$0.06

$0.07

$0.06

$0.10

$0.00

$0.00

$0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$8.09 $7.84 $20.73 $0.06 $1.20 $0.82 $0.01 $2.10

$22.83

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

H Hose, Trans Cooler 021304-N0502-37

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H Hose, Trans Cooler 021304-N0502-37 720 5.00 1.00

H Rubber Tube, 17 mm Diam

021304-N0502-38

H Pipe, Tube Asm, Trans Cooler Asm. 021304-N0502-39

H Fitting, Tube Asm, 021304-N0502-40

021304-N0502-40A

021304-N0502-40B

H Fluid Pipe Fitting Exchanger Asm. 021304-N0502-41

021304-N0502-41A

720 5.00 1.00

6000 0.60 1.00

113 32.00 0.50

327 11.00 1.00

159 22.67 1.50

554 6.50 1.00

327 11.00 1.00

309 11.67 1.50

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

021304-N0502-41B

H Locator Bracket, Exchanger 021304-N0502-42

021304-N0502-42A

H RH Mounting Bracket, Exchanger 021304-N0502-43

021304-N0502-43A

021304-N0502-43B

H Locator Bracket, Exchanger 021304-N0502-44

021304-N0502-44A

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

900 4.00 1.00

327 11.00 1.00

900 4.00 1.00

327 11.00 1.00

831 4.33 1.50

900 4.00 1.00

327 11.00 1.00

900 4.00 1.00

H LH Mounting Bracket, Exchanger 021304-N0502-45

021304-N0502-45A

021304-N0502-45B

H Return Tube, Exchanger Asm. 021304-N0502-46

H Tank Endcap, Exchanger 021304-N0502-47

H Tank Endcap, Exchanger 021304-N0502-48

H LH Outboard Tank, Exchanger 021304-N0502-49

H RH Outboard Tank, Exchanger 021304-N0502-50

H Inboard Tank, Exchanger 021304-N0502-51

H Inboard Tank, Exchanger 021304-N0502-52

H Tube Exchanger Asm 021304-N0502-53

021304-N0502-54

H Fin Exchanger Asm 021304-N0502-55

H Hose Asm, Trans Cooler 021304-N0502-56

H Tube Asm, Trans Cooler Asm. 021304-N0502-57

H Tube & Hose Asm, Trans Cooler Asm. 021304-N0502-58

H RH Outboard Tank, Exchanger 021304-N0502-59

H LH Outboard Tank, Exchanger 021304-N0502-60

H Cooler Core Asm, Exchanger 021304-N0502-61

H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62

327 11.00 1.00

831 4.33 1.50

900 4.00 1.00

100 36.00 0.50

5143 0.70 0.50

5143 0.70 0.50

5143 0.70 0.50

5143 0.70 0.50

2000 1.80 0.50

2000 1.80 0.50

327 11.00 1.00

3600 1.00 0.50

4500 0.80 0.50

144 25.00 0.50

189 19.00 1.00

121 29.67 1.50

158 22.80 1.50

134 26.80 1.50

118 30.60 2.50

H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62 144 25.00 0.50

H Exchanger Asm, Trans Cooler Asm. 021304-N0502-62A

021304-N0502-62B

021304-N0502-62C

021304-N0502-62

144 25.00 0.50

257 14.00 0.25

124 29.00 1.50

257 14.00 0.25

212 17.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H Oetiker Clamp, Medium (26.5mm) 021304-N0502-63

H Hose Clamp, Medium (27mm) 021304-N0502-64

H O-Ring, 18.5 x 2.5 mm 021304-N0502-65

H Heat Shrink Fabric Tube, 21 mmm Diam 021304-N0502-66

H Bolt, Line Asm to Exchanger 021304-N0502-67

H Label, Cooler Asm. 021304-N0502-68

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Low Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Cooler Line Asm D Part Number: 021370-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 H Trans Cooler Line, E Motor Cooling 021370-N0502-69 1 Extrude T2/T3 Comp./Ext. Mold, SSLC

Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS

2 H Trans Cooler Line, E Motor Cooling 021370-N0502-69 1 Extrude T2/T3 Comp./Ext. Mold, SSLC 293 1 1 1 0.5426 $1.32 $56.05 $35.94 $35.94 $0.72 $0.19 $0.12 $1.03 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.14 $1.14 $0.72

3 H Trans Cooler Line Asm, E Motor Cooling 021370-N0502-70 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 185 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.21 $0.16 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.41 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Low Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Cooler Line Asm D Part Number: 021370-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 H Hose Clamp, Medium (24mm) 021370-N0502-71 1 S $0.00 $0.22 $0.00 $0.22 $0.22

5 H Hose Clamp, Medium (27mm) 021370-N0502-72 1 S $0.00 $0.23 $0.00 $0.23 $0.23

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 5 H Hose Clamp, Medium (27mm) 021370-N0502-72 1 S $0.00 $0.23 $0.00 $0.23 $0.23

4 H Strap On Christmas Tree Clip (# 30) 021370-N0502-73 1 S $0.00 $0.04 $0.00 $0.04 $0.04

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Low Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Cooler Line Asm D Part Number: 021370-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$1.21

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $2.04

T1 or OEM Total Manufacturing Cost: $1.21 $0.40 $0.29 $1.89 $0.00 $0.08 $0.06 $0.00 $0.14 $2.04

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.12 $0.08 $0.02 $0.23

Base Cost Impact to Vehicle: $1.21 $0.40 $0.29 $1.89 $0.01 $0.21 $0.14 $0.02 $0.37 $2.27 $0 $0

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $2.28

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Piece Price Per Pallet/Rack Price Per Pallet/Rack Price Per Pallet/Rack Price Per Pallet/Rack Price Per Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Low Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: H Trans Cooler Line Asm D Part Number: 021370-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.1 1.0

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

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

H Trans Cooler Line, E Motor Cooling 021370-N0502-69

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

H Trans Cooler Line, E Motor Cooling 021370-N0502-69 $0.19 $0.12 $1.03 $0.00 $0.06 $0.04 $0.00 $0.11 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12.3 1 1 12.3 1.0 1.0

H Trans Cooler Line Asm, E Motor Cooling 021370-N0502-70

$0.19 $0.12 $1.03 $0.00 $0.06 $0.04 $0.00 $0.11 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12.3 1 1 12.3 1.0 1.0

$0.21 $0.16 $0.37 $0.00 $0.02 $0.01 $0.00 $0.04 Retract hose clamps and slip on hose. Strap on xmas treee and attach zip tie 5 2 10 100 47 4700 96 37.60 85% 113 31.96 39 4 1 39 1.0 2.0

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

H Hose Clamp, Medium (24mm) 021370-N0502-71

H Hose Clamp, Medium (27mm) 021370-N0502-72

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00

$0.00

$0.00

$0.22

H Hose Clamp, Medium (27mm) 021370-N0502-72 $0.23

H Strap On Christmas Tree Clip (# 30) 021370-N0502-73 $0.04

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.40 $0.29 $1.89 $0.00 $0.08 $0.06 $0.00 $0.14

$2.04

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

H Trans Cooler Line, E Motor Cooling 021370-N0502-69

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H Trans Cooler Line, E Motor Cooling 021370-N0502-69 293 12.30 1.00

H Trans Cooler Line Asm, E Motor Cooling 021370-N0502-70

293 12.30 1.00

185 19.50 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

H Hose Clamp, Medium (24mm) 021370-N0502-71

H Hose Clamp, Medium (27mm) 021370-N0502-72

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H Hose Clamp, Medium (27mm) 021370-N0502-72

H Strap On Christmas Tree Clip (# 30) 021370-N0502-73

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
01 14 H Trans & DC Cooling System QTY $$$

H Trans & DC Cooling System 2.48

x H Bolt Trans Coolant Bottle1 0.07

x H Nut Trans Coolant Bottle1 0.07

x H Bolt, Trans Coolant Pump2 0.14

x H Bolt, Trans Cooler to FEM1 0.07

x H Bolt, Trans Cooler to FEM1 0.07

xA H Bottle Asm w/Hose, Trans Coolant1 0.19

x A1 H Bottle Asm,Trans Coolant1 0.35

x H Label, Trans Cooler Bottle1 0.11

x A1A H Bottle, Trans Coolant, Welded1 0.48

x H Bottle Bottom, Trans Coolant, Molded1 0.88

x H Bottle Top, Trans Coolant, Molded1 0.46

x A1B H Tube, Trans Coolant Bottle1 0.10

x A1C H Cap, Trans Coolant Bottle1 0.29

x A2 H Hose Asm, Coolant, Trans to Bottle1 0.35

x H Hose, Coolant, Trans to Bottle1 0.36

x H Sheath, (15/16"), Bottle to Trans Hose1 0.21

x H Hose Clamp, Medium (24mm)1 0.26

x H Hose Clamp, Medium (22mm)1 0.24

xB H Trans Coolant Pump Sub Asm.1 0.44

x B1 H Trans Coolant Pump w/Mount1 0.36

x H Trans Coolant Pump1 29.68

x H Isolation Ring, Mount, Coolant Pump1 0.15

x H Clamp, Mount, Coolant Pump1 0.12

x B1A H Bracket Asm, Mount, Cololant Pump1 0.15

x H Bracket, Mount, Coolant Pump1 0.82

x H Foam Pad, Self Stick, Pump Bracket1 0.01

x B2 H Coolant Line Asm, Pump to E motor1 0.30

x H Coolant Line, Pump to E Motor 1 0.79

x H Hose Clamp, Medium (27mm) 2 0.54

x B3 H Coolant Line Asm, DC-DC to Pump1 0.72

x H Coolant Line, DC-DC to Pump1 1.36

x H Sheath, (15/16"), Pump to Dc-Dc Module1 1.37

x H Hose Clamp, Medium (27mm) 2 0.54

x H Strap On Hose Clip (#7)1 0.05

x H Clamp On Christmas Tree Clip1 0.09

x H Zip Tie1 0.01

xC H Cooler Asm, Trans & DC-DC Mod 1 0.24

x H Bolt, Line Asm to Exchanger1 0.07

x H Label, Cooler Asm.1 0.11

x C1 H Exchanger Asm, Trans Cooler Asm.1 1.34

x H Fluid Pipe Fitting Exchanger Asm.1 1.13

x H RH Mounting Bracket, Exchanger1 0.73

x H Locator Bracket, Exchanger1 0.50

x C1A H Cooler Core Asm, Exchanger1 1.77

x H Tube Exchanger Asm 17 9.58 x H Fin Exchanger Asm 16 0.91
x C1B H LH Outboard Tank, Exchanger 0.79 x H LH Outboard Tank, Exchanger 1 0.09 x H Tank Endcap, Exchanger 2 0.05 x H Inboard Tank, Exchanger 1 0.12 x H Return Tube, Exchanger Asm. 1 0.94 x H LH Mounting Bracket, Exchanger 1 0.75 x H Locator Bracket, Exchanger 1 0.53 x C1C H RH Outboard Tank, Exchanger 1 0.67 x H Inboard Tank, Exchanger, 1 0.12 x H Tank Endcap, Exchanger 2 0.05 x H RH Outboard Tank, Exchanger 1 0.09 x C2 H Tube & Hose Asm, Trans Cooler Asm. 1 1.03 x H O-Ring, 18.5 x 2.5 mm 1 0.07 x H Rubber Tube, 17 mm Diam 1 0.04 x H Heat Shrink Fabric Tube, 21 mmm Diam 1 0.08 x C2A H Tube Asm, Trans Cooler Asm. 1 0.44 x H Pipe, Tube Asm, Trans Cooler Asm. 1 0.92 x H Fitting, Tube Asm, 1 1.80 x C2B H Hose Asm, Trans Cooler 1 0.29 x H Hose, Trans Cooler 1 0.55 x H Oetiker Clamp, Medium (26.5mm) 1 0.29 x H Hose Clamp, Medium (27mm) 1 0.27 x D H Trans Cooler Line Asm, E Motor Cooling 1 0.45 x H Trans Cooler Line, E Motor Cooling 1 1.31 x H Hose Clamp, Medium (24mm) 1 0.25 x H Hose Clamp, Medium (27mm) 1 0.27 x H Strap On Christmas Tree Clip (# 30) 1 0.04

108 73.36
Comments

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

x

Commodity

Commodity

x

x
x

x

x

Commodity

Commodity

x

Commodity?

26.36 Commodity

Commodity

Commodity

2.32 Commodity
Indented Bill of Materials

H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H Bottle Asm w/Hose, Trans H Bottle Asm 0.8123 lb 0.8123 lb Coolant w/Hose, Trans 

Coolant

1 H Bottle Asm, Trans Coolant H Bottle Asm, 1 # 0.6344 lb # 0.6344 lb

Trans Coolant

2 H Bottle, Trans Coolant H Bottle, Trans 1 # 0.6052 lb # 0.6052 lb

Coolant

3 H Bottle, Trans Coolant, H Bottle, Trans 1 Polypropylene # 0.5911 lb # 0.5911 lb

Welded Coolant, 

Welded

4 H Bottle Bottom, Trans H Bottle 1 Polypropylene # 0.4138 lb # 0.4138 lb

Coolant, Molded Bottom, Trans 

Coolant, 

Molded

5 H Bottle Bottom, Trans H Bottle 1 Polypropylene # 0.4138 lb # 0.4138 lb

Coolant, Material Bottom, Trans 

Coolant, 

Material

4 H Bottle Top, Trans Coolant, H Bottle Top, 1 Polypropylene # 0.1773 lb # 0.1773 lb

Molded Trans Coolant, 

Molded

5 H Bottle Top, Trans Coolant, H Bottle Top, 1 Polypropylene # 0.1773 lb # 0.1773 lb

Material Trans Coolant, 

Material

3 H Tube, Trans Coolant Bottle H Tube, Trans 1 Stainless Steel # 0.0141 lb # 0.0141 lb

Coolant Bottle #

4 H Tube, Trans Coolant Bottle, H Tube, Trans 1 Stainless Steel # 0.0141 lb # 0.0141 lb

Material Coolant Bottle, #

Material

2 H Cap, Trans Coolant Bottle H Cap, Trans 1 Polypropylene # 0.0291 lb # 0.0291 lb

Coolant Bottle

3 H Cap, Trans Coolant Bottle, H Cap, Trans 1 Polypropylene # 0.0291 lb # 0.0291 lb

Molded Coolant Bottle, 

Molded

4 H Cap, Trans Coolant Bottle, H Cap, Trans 1 Polypropylene # 0.0291 lb # 0.0291 lb

Material Coolant Bottle, 

Material

Design Profit®
Page 

1 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H Label, Trans Cooler Bottle H Label, Trans 1 Commodity 0.0001 lb 0.0001 lb

Cooler Bottle Pricing

1 H Hose Asm, Coolant, Trans H Hose Asm, 1 # 0.1779 lb # 0.1779 lb

to Bottle Coolant, Trans 

to Bottle

2 H Hose, Coolant, Trans to H Hose, 1 SBR # 0.1364 lb # 0.1364 lb

Bottle, Extruded Coolant, Trans 

to Bottle, 

Extruded

3 H Hose, Coolant, Trans to H Hose, 1 SBR # 0.1364 lb # 0.1364 lb

Bottle, Material Coolant, Trans 

to Bottle, 

Material

2 H Sheath, (15/16"), Bottle to H Sheath, 1 Commodity # 0.0048 lb # 0.0048 lb

Trans Hose (15/16"), Bottle Pricing

to Trans Hose

2 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0200 lb # 0.0200 lb

(24mm) Medium Pricing

(24mm)

2 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0167 lb # 0.0167 lb

(22mm) Medium Pricing

(22mm)

0 H Bolt Trans Coolant Bottle H Bolt Trans 1 Commodity # 0.0208 lb # 0.0208 lb

Coolant Bottle Pricing

0 H Nut Trans Coolant Bottle H Nut Trans 1 Commodity # 0.0106 lb # 0.0106 lb

Coolant Bottle Pricing

0 H Trans Coolant Pump Sub H Trans 1 # 1.6571 lb # 1.6571 lb

Asm Coolant Pump 

Sub Asm

1 H Trans Coolant Pump H Trans 1 # 0.6446 lb # 0.6446 lb

w/Mount Coolant Pump 

w/Mount

2 H Trans Coolant Pump H Trans 1 Commodity # 0.3778 lb # 0.3778 lb

Coolant Pump Pricing

2 H Isolation Ring, Mount, H Isolation 1 SBR # 0.0395 lb # 0.0395 lb

Coolant Pump Ring, Mount, 

Coolant Pump

3 H Isolation Ring, Mount, H Isolation 1 SBR # 0.0395 lb # 0.0395 lb

Coolant Pump, Material Ring, Mount, 

Coolant Pump, 

Material
Design Profit®

Page 2 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H Clamp, Mount, Coolant H Clamp, 1 PA66 0.0343 lb 0.0343 lb

Pump Mount, 

Coolant Pump

3 H Clamp, Mount, Coolant H Clamp, 1 PA66 # 0.0343 lb # 0.0343 lb

Pump, Material Mount, Coolant 

Pump, Material

2 H Bracket Asm, Mount, H Bracket 1 # 0.1930 lb # 0.1930 lb

Coolant Pump Asm, Mount, 

Coolant Pump

3 H Bracket, Mount, Coolant H Bracket, 1 Steel - 1008 # 0.1929 lb # 0.1929 lb

Pump Mount, 

Coolant Pump

4 H Bracket, Mount, Coolant H Bracket, 1 Steel - 1008 # 0.1929 lb # 0.1929 lb

Pump, Washed Mount, 

Coolant Pump, 

Washed

5 H Bracket, Mount, Coolant H Bracket, 1 Steel - 1008 # 0.1929 lb # 0.1929 lb

Pump, Stamped Mount, 

Coolant Pump, 

Stamped

6 H Bracket, Mount, Coolant H Bracket, 1 Steel - 1008 # 0.1929 lb # 0.1929 lb

Pump, Material Mount, Coolant 

Pump, Material

3 H Foam Pad, Self Stick, Pump H Foam Pad, 1 Commodity # 0.0001 lb # 0.0001 lb

Bracket Self Stick, Pricing

Pump Bracket

1 H Coolant Line Asm, Pump H Coolant Line 1 # 0.3916 lb # 0.3916 lb

to E Motor Asm, Pump to 

E Motor

2 H Coolant Line, Pump to E H Coolant 1 EPDM # 0.3404 lb # 0.3404 lb

Motor Line, Pump to 

E Motor

3 H Coolant Line, Pump to E H Coolant Line, 1 EPDM # 0.3404 lb # 0.3404 lb

Motor, Material Pump to E 

Motor, Material

2 H Hose Clamp, Medium H Hose Clamp, 2 Commodity # 0.0256 lb # 0.0512 lb

(27mm) Medium Pricing

(27mm)

1 H Coolant Line Asm, DC-DC H Coolant Line 1 # 0.6209 lb # 0.6209 lb

to Pump Asm, DC-DC to 

Pump
Design Profit®

Page 3 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H Coolant Line, DC-DC to H Coolant 1 0.5021 lb 0.5021 lb

Pump Line, DC-DC to 

Pump

3 H Coolant Line, DC-DC to H Coolant Line, 1 EPDM # 0.5021 lb # 0.5021 lb

Pump, Material DC-DC to 

Pump, Material

2 H Sheath, (15/16"), Pump to H Sheath, 1 Commodity # 0.0381 lb # 0.0381 lb

Dc-Dc Module (15/16"), Pump Pricing

to Dc-Dc 

Module

2 H Hose Clamp, Medium H Hose Clamp, 2 Commodity # 0.0256 lb # 0.0512 lb

(27mm) Medium Pricing

(27mm)

2 H Strap On Hose Clip (#7) H Strap On 1 Commodity # 0.0096 lb # 0.0096 lb

Hose Clip (#7) Pricing

2 H Clamp On Christmas Tree H Clamp On 1 PA66 # 0.0199 lb # 0.0199 lb

Clip Christmas 

Tree Clip

3 H Clamp On Christmas Tree H Clamp On 1 PA66 # 0.0199 lb # 0.0199 lb

Clip, Material Christmas Tree 

Clip, Material

0 H Bolt, Trans Coolant Pump H Bolt, Trans Coolant Pump H Bolt, Trans H Bolt, Trans 2 Commodity Commodity # 0.0208 lb 0.0208 lb # 0.0416 lb 0.0416 lb

Coolant Pump Pricing

0 H Cooler Asm, Trans & H Cooler Asm, 1 # 3.3818 lb # 3.3818 lb

DC-DC Mod Trans & 

DC-DC Mod

1 H Exchanger Asm, Trans H Exchanger 1 Aluminum- Mn # 2.8850 lb # 2.8850 lb

Cooler Asm Asm, Trans - 30xx

Cooler Asm

2 H Exchanger Asm, Trans H Exchanger 1 Aluminum- Mn # 2.8849 lb # 2.8849 lb

Cooler, Painted Asm, Trans - 30xx

Cooler, 

Painted

3 H Exchanger Asm, Trans H Exchanger 1 Aluminum- Mn # 2.8849 lb # 2.8849 lb

Cooler, Washed Asm, Trans - 30xx

Cooler, 

Washed

4 H Exchanger Asm, Trans H Exchanger 1 Aluminum- Mn # 2.8849 lb # 2.8849 lb

Cooler, Brazed Asm, Trans - 30xx

Cooler, Brazed

Design Profit®
Page 

4 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H Exchanger Asm, H Exchanger Aluminum- Mn # 2.8849 lb # 2.8849 lb

Assembled Loose Asm, - 30xx

Assembled 

Loose

6 H Cooler Core Asm, H Cooler Core 1 # 2.3803 lb # 2.3803 lb

Exchanger Asm, 

Exchanger

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

Design Profit®
Page 

5 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

8 H Tube Exchanger Asm, H Tube Aluminum- Mn 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

Design Profit®
Page 

6 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

8 H Fin, Exchanger Asm, H Fin, Aluminum- Mn - 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded
Design Profit®

Page 7 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Tota

(Total)

9 H Tube Exchanger Asm, H Tube Commodity # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

Design Profit®
Page 

8 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

7 H Tube Exchanger Asm, H Tube Aluminum- Mn # 0.1075 lb #

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material
Design Profit®

Page 9 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

7 H Fin, Exchanger Asm, Roll H Fin, Aluminum- Mn # 0.0346 lb #

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

Design Profit®
Page 

# of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

8 H Tube Exchanger Asm, H Tube Aluminum- Mn 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

7 H Fin, Exchanger Asm, Roll H Fin, 1 Aluminum- Mn # 0.0346 lb # 0.0346 lb

Formed Exchanger - 30xx

Asm, Roll 

Formed

8 H Fin, Exchanger Asm, H Fin, 1 Aluminum- Mn - # 0.0346 lb # 0.0346 lb

Material Exchanger 30xx - Clad

Asm, Material

7 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Deburred Exchanger - 30xx

Asm, Deburred

8 H Tube Exchanger Asm, H Tube 1 Aluminum- Mn # 0.1075 lb # 0.1075 lb

Extruded Exchanger - 30xx

Asm, Extruded

9 H Tube Exchanger Asm, H Tube 1 Commodity # 0.1075 lb # 0.1075 lb

Material Exchanger Pricing

Asm, Material

6 H LH Outboard Tank, H LH Outboard 1 # 0.1813 lb # 0.1813 lb

Exchanger Tank, 

Exchanger

7 H LH Outboard Tank, H LH Outboard 1 Al-Mn - 30xx - # 0.0677 lb # 0.0677 lb

Exchanger, Stamped Tank, Clad

Exchanger, 

Stamped

8 H LH Outboard Tank, H LH Outboard 1 Al-Mn - 30xx - # 0.0677 lb # 0.0677 lb

Exchanger, Material Tank, Clad

Exchanger, 

Material

7 H Tank Endcap, Exchanger H Tank 2 Al-Mn - 30xx - # 0.0057 lb # 0.0114 lb

Endcap, Clad

Exchanger

8 H Tank Endcap, Exchanger, H Tank Endcap, 1 Al-Mn - 30xx - # 0.0057 lb # 0.0114 lb

Material Exchanger, Clad

Material

7 H Inboard Tank, Exchanger, H Inboard 1 Al-Mn - 30xx - # 0.0669 lb # 0.0669 lb

Stamping Tank, Clad

Exchanger, 

Stamping

Design Profit®
Page 

# of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

8 H Inboard Tank, Exchanger, H Inboard Tank, Al-Mn - 30xx - 0.0669 lb

Material Exchanger, Clad

Material

7 H Return Tube, Exchanger H Return Tube, 1 Aluminum- Mn # 0.0353 lb # 0.0353 lb

Asm Exchanger - 30xx

Asm

8 H Return Tube, Exchanger, H Return Tube, 1 Aluminum- Mn # 0.0353 lb # 0.0353 lb

Material Exchanger, - 30xx

Material

6 H LH Mounting Bracket, H LH Mounting 1 Aluminum- Mn # 0.0288 lb # 0.0288 lb

Exchanger, Deburred Bracket, - 30xx

Exchanger, 

Deburred

7 H LH Mounting Bracket, H LH Mounting 1 Aluminum- Mn # 0.0288 lb # 0.0288 lb

Exchanger, Machined Bracket, - 30xx

Exchanger, 

Machined

8 H LH Mounting Bracket, H LH Mounting 1 Aluminum- Mn # 0.0288 lb # 0.0288 lb

Exchanger, Extruded Bracket, - 30xx

Exchanger, 

Extruded

9 H LH Mounting Bracket, H LH Mounting 1 Commodity # 0.0288 lb # 0.0288 lb

Exchanger, Material Bracket, Pricing

Exchanger, 

Material

6 H Locator Bracket, H Locator 1 Aluminum- Mn # 0.0299 lb # 0.0299 lb

Exchanger, Deburred Bracket, - 30xx

Exchanger, 

Deburred

7 H Locator Bracket, H Locator 1 Aluminum- Mn # 0.0299 lb # 0.0299 lb

Exchanger, Extruded Bracket, - 30xx

Exchanger, 

Extruded

8 H Locator Bracket, Exchanger, H Locator 1 Commodity # 0.0299 lb # 0.0299 lb

Material Bracket, Pricing

Exchanger, 

Material

6 H RH Outboard Tank, H RH 1 # 0.1460 lb # 0.1460 lb

Exchanger Outboard 

Tank, 

Exchanger

Design Profit®
Page 

# of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

7 H Inboard Tank, Exchanger, H Inboard Al-Mn - 30xx - # 0.0669 lb #

Stamping Tank, Clad

Exchanger, 

Stamping

8 H Inboard Tank, Exchanger, H Inboard Tank, 1 Al-Mn - 30xx - # 0.0669 lb # 0.0669 lb

Material Exchanger, Clad

Material

7 H Tank Endcap, Exchanger H Tank 2 Al-Mn - 30xx - # 0.0057 lb # 0.0114 lb

Endcap, Clad

Exchanger

8 H Tank Endcap, Exchanger, H Tank Endcap, 1 Al-Mn - 30xx - # 0.0057 lb # 0.0114 lb

Material Exchanger, Clad

Material

7 H RH Outboard Tank, H RH 1 Al-Mn - 30xx - # 0.0677 lb # 0.0677 lb

Exchanger, Stamped Outboard Clad

Tank, 

Exchanger, 

Stamped

8 H RH Outboard Tank, H RH Outboard 1 Al-Mn - 30xx - # 0.0677 lb # 0.0677 lb

Exchanger, Material Tank, Clad

Exchanger, 

Material

6 H Fluid Pipe Fitting H Fluid Pipe Fitting H Fluid Pipe H Fluid Pipe 1 Aluminum- Mn uminum- Mn # 0.0594 lb 0.0594 lb # 0.0594 lb 0.0594 lb

Exchanger Asm, Extruded Fitting - 30xx

Exchanger 

Asm, Extruded

7 H Fluid Pipe Fitting H Fluid Pipe 1 Aluminum- Mn # 0.0594 lb # 0.0594 lb

Exchanger Asm, Machined Fitting - 30xx

Exchanger 

Asm, 

Machined

8 H Fluid Pipe Fitting H Fluid Pipe 1 Aluminum- Mn # 0.0594 lb # 0.0594 lb

Exchanger Asm, Extruded Fitting - 30xx

Exchanger 

Asm, 

Machined-1

9 H Fluid Pipe Fitting Exchanger H Fluid Pipe 1 Commodity # 0.0594 lb # 0.0594 lb

Asm, Material Fitting Price

Exchanger 

Asm, Material
Design Profit®

Page # of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H RH Mounting Bracket, H RH 1 Aluminum- Mn # 0.0293 lb 0.0293 lb

Exchanger, Deburred Mounting - 30xx

Bracket, 

Exchanger, 

Deburred

7 H RH Mounting Bracket, H RH 1 Aluminum- Mn # 0.0293 lb # 0.0293 lb

Exchanger, Machined Mounting - 30xx

Bracket, 

Exchanger, 

Machined

8 H RH Mounting Bracket, H RH 1 Aluminum- Mn # 0.0293 lb # 0.0293 lb

Exchanger, Extruded Mounting - 30xx

Bracket, 

Exchanger, 

Extruded

9 H RH Mounting Bracket, H RH Mounting 1 Commodity # 0.0293 lb # 0.0293 lb

Exchanger, Material Bracket, Pricing

Exchanger, 

Material

6 H Locator Bracket, H Locator 1 Aluminum- Mn # 0.0299 lb # 0.0299 lb

Exchanger, Deburred Bracket, - 30xx

Exchanger, 

Deburred

7 H Locator Bracket, H Locator 1 Aluminum- Mn # 0.0299 lb # 0.0299 lb

Exchanger, Extruded Bracket, - 30xx

Exchanger, 

Extruded

8 H Locator Bracket, Exchanger, H Locator 1 Commodity # 0.0299 lb # 0.0299 lb

Material Bracket, Pricing

Exchanger, 

Material

2 H Label, Exchanger Asm H Label, 1 Commodity # 0.0001 lb # 0.0001 lb

Exchanger Asm Pricing

1 H Tube & Hose Asm, Trans H Tube & Hose 1 # 0.4584 lb # 0.4584 lb

Cooler Asm Asm, Trans 

Cooler Asm

2 H Tube Asm, Trans Cooler H Tube Asm, 1 # 0.1740 lb # 0.1740 lb

Asm Trans Cooler 

Asm

3 H Tube Asm, Trans Cooler H Tube Asm, 1 Aluminum- Mn # 0.1740 lb # 0.1740 lb

Asm, Pressed Trans Cooler - 30xx

Asm, Pressed

Design Profit®
Page 

# of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H Pipe, Tube Asm, Trans H Pipe, Tube 1 # 0.1001 lb # 0.1001 lb

Cooler Asm, Trans 

Cooler

5 H Pipe, Tube Asm, Trans H Pipe, Tube 1 Commodity # 0.1001 lb # 0.1001 lb

Cooler, Material Asm, Trans Pricing

Cooler, Material

4 H Fitting, Tube Asm, Washed H Fitting, Tube 1 # 0.0739 lb # 0.0739 lb

Asm, Washed

5 H Fitting, Tube Asm, H Fitting, Tube 1 # 0.0739 lb # 0.0739 lb

Deburred Asm, Deburred

6 H Fitting, Tube Asm, H Fitting, Tube 1 # 0.0739 lb # 0.0739 lb

Machined Asm, 

Machined

7 H Fitting, Tube Asm, H Fitting, Tube 1 # 0.0739 lb # 0.0739 lb

Extruded Asm, Extruded

8 H Fitting, Tube Asm, Material H Fitting, Tube 1 # 0.0739 lb # 0.0739 lb

Asm, Material

2 H O-Ring, 18.5 x 2.5 mm H O-Ring, 18.5 1 Commodity # 0.0007 lb # 0.0007 lb

x 2.5 mm Pricing

2 H Rubber Tube, 17 mm Diam H Rubber 1 EDPM # 0.0080 lb # 0.0080 lb

Tube, 17 mm 

Diam

3 H Rubber Tube, 17 mm Diam, H Rubber Tube, 1 EDPM # 0.0080 lb # 0.0080 lb

Material 17 mm Diam, 

Material

2 H Heat Shrink Fabric Tube, 21 H Heat Shrink 1 Commodity # 0.0054 lb # 0.0054 lb

mm Diam Fabric Tube, 21 Pricing

mm Diam

2 H Hose Asm, Trans Cooler H Hose Asm, 1 # 0.2703 lb # 0.2703 lb

Trans Cooler

3 H Hose Asm, Trans Cooler H Hose, Trans 1 EPDM # 0.2270 lb # 0.2270 lb

Cooler

4 H Hose, Trans Cooler, Material H Hose, Trans 1 EPDM # 0.2270 lb # 0.2270 lb

Cooler, Material

3 H Oetiker Clamp, Medium H Oetiker 1 Commodity # 0.0177 lb # 0.0177 lb

(26.5mm) Clamp, Medium Pricing

(26.5mm)

3 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0256 lb # 0.0256 lb

(27mm) Medium Pricing

(27mm)
Design Profit®

Page # of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

(Total)

H Bolt, Line Asm to Exchanger H Bolt, Line 1 Commodity # 0.0384 lb # 0.0384 lb

Asm to Pricing

Exchanger

0 H Bolt, Trans Cooler to FEM H Bolt, Trans 1 Commodity # 0.0230 lb # 0.0230 lb

Cooler to FEM Pricing

0 H Bolt, Trans Cooler to FEM H Bolt, Trans 1 Commodity # 0.0230 lb # 0.0230 lb

Cooler to FEM Pricing

0 H Trans Cooler Line Asm, E H Trans Cooler 1 # 0.5914 lb # 0.5914 lb

Motor Cooling Line Asm, E 

Motor Cooling

1 H Trans Cooler Line, E Motor H Trans Cooler 1 # 0.5426 lb # 0.5426 lb

Cooling Line, E Motor 

Cooling

2 H Trans Cooler Line, E Motor H Trans Cooler 1 # 0.5426 lb # 0.5426 lb

Cooling, Material Line, E Motor 

Cooling, 

Material

1 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0200 lb # 0.0200 lb

(24mm) Medium Pricing

(24mm)

1 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0256 lb # 0.0256 lb

(27mm) Medium Pricing

(27mm)

1 H Strap On Christmas Tree H Strap On 1 Commodity # 0.0032 lb # 0.0032 lb

Clip (#30) Christmas Tree Pricing

Clip (#30)

Assembly Totals Report Totals Preassembled Totals

Analyzed Subs: # Piece Cost (Total): Analyzed Subs:

Unanalyzed Subs: 2 Unanalyzed Subs:

Weight (Total): 6.5616 lb

Parts: # Parts:

Fasteners: # Fasteners:

Parts+Unanaly # zed: Parts+Unanalyzed:

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# of#

Copyright 2010 © Design Profit, Inc.








2.8849 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

eight (Total)

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

eight (Total)

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

Weight (Tota

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

ght (Total)

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

ght (Total)

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

eight (Total)

0.1075 lb

0.1075 lb

0.0346 lb

0.0346 lb

0.1075 lb

0.1075 lb

0.1075 lb

0.0677 lb

0.0677 lb

0.0114 lb

0.0114 lb

0.0669 lb

eight (Total)

0.0669 lb

0.0353 lb

0.0353 lb

0.0288 lb

0.0288 lb

0.0288 lb

0.0299 lb

0.0299 lb

ght (Total)

0.0669 lb

0.0669 lb

0.0114 lb

0.0114 lb

0.0677 lb

0.0677 lb

0.0594 lb

0.0594 lb

0.0594 lb

0.0293 lb

0.0293 lb

0.0293 lb

0.0293 lb

0.0299 lb

0.0299 lb

0.1001 lb

0.0739 lb

0.0739 lb



Assembly Report

H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$83.31 Tool H Trans & DC-DC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cooling System

- - - Install Trans Coolant Bottle Asm - - - - - -

$43.52 Subassembly H Trans & DC-DC H Bottle Asm w/Hose, Trans H Bottle Asm 3.0000 sec 3.0000 sec - $0.07 1

Cooling System Coolant w/Hose, Trans 

Coolant

$43.52 Tool H Bottle Asm First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

w/Hose, Trans 

Coolant

$43.52 Subassembly H Bottle Asm H Bottle Asm, Trans Coolant H Bottle Asm, 3.0000 sec 3.0000 sec - $0.04 1

w/Hose, Trans Trans Coolant

Coolant

$43.52 Tool H Bottle Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans Coolant

$43.52 Subassembly H Bottle Asm, H Bottle, Trans Coolant H Bottle, Trans 3.0000 sec 3.0000 sec - $0.04 1

Trans Coolant Coolant

$43.52 Tool H Bottle, Trans Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant

$43.52 Subassembly H Bottle, Trans H Bottle, Trans Coolant, Welded H Bottle, Trans 3.0000 sec 3.0000 sec - $0.04 1

Coolant Coolant, Welded

$43.52 Tool H Bottle, Trans Vibration Welder 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant, Welded

###### P.-P. Part H Bottle, Trans H Bottle Bottom, Trans Coolant, H Bottle Bottom, 3.0000 sec 3.0000 sec - $0.04 1

Coolant, Welded Molded Trans Coolant, 

Molded

###### Tool H Bottle Bottom, Inj Mold Machine 1500-3000 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans Coolant, 

Molded

###### Part H Bottle Bottom, H Bottle Bottom, Trans Coolant, H Bottle Bottom, 0.0000 sec 5.3670 sec $0.40 $0.23 1

Trans Coolant, Material Trans Coolant, 

Molded Material

- - - Raw Material Req 0.461 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 248mm L x 172mm W x - - - - - -

134mm H

Design Profit ®
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Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$90.59 P.-P. Part H Bottle, Trans H Bottle Top, Trans Coolant, H Bottle Top, 5.0000 sec 5.0000 sec - $0.06 1

Coolant, Welded Molded Trans Coolant, 

Molded

$90.59 Tool H Bottle Top, Inj Molding Machine 800-1500 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans Coolant, Ton

Molded

$90.59 Part H Bottle Top, H Bottle Top, Trans Coolant, H Bottle Top, 0.0000 sec 4.7770 sec $0.18 $0.12 1

Trans Coolant, Material Trans Coolant, 

Molded Material

- - - Raw Material Req 0.205 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 248mm L x 165mm W x - - - - - -

24mm H

$43.52 Fastening H Bottle, Trans Vibration Weld 3.0000 sec 3.0000 sec $0.00 $0.04 1

Coolant, Welded

$44.85 P.-P. Part H Bottle, Trans H Tube, Trans Coolant Bottle H Tube, Trans 5.0000 sec 5.0000 sec - $0.06 1

Coolant Coolant Bottle

$44.85 Tool H Tube, Trans Tube Cutter 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Bottle

$44.85 Part H Tube, Trans H Tube, Trans Coolant Bottle, H Tube, Trans 0.0000 sec 0.0000 sec $0.02 $0.00 1

Coolant Bottle Material Coolant Bottle, 

Material

$44.85 Operation H Tube, Trans Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Coolant Bottle

$44.85 Material Mod. H Tube, Trans Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 1

Coolant Bottle

$44.85 Operation H Tube, Trans Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Coolant Bottle

- - - Raw Mat: 0.0142 lbs SS304 (12D - - - - - -

x 0.53Wall)mm

- - - Box size of finished part - - - - - -

0.53Dmm x 41.3Lmm

$43.52 Fastening H Bottle, Trans Press Together 3.0000 sec 3.0000 sec $0.00 $0.04 1

Coolant

$43.52 P.-P. Part H Bottle Asm, H Cap, Trans Coolant Bottle H Cap, Trans 7.0000 sec 7.0000 sec - $0.08 1

Trans Coolant Coolant Bottle

$43.52 Tool H Cap, Trans Paint Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Bottle

$28.80 P.-P. Part H Cap, Trans H Cap, Trans Coolant Bottle, H Cap, Trans 3.0000 sec 3.0000 sec - $0.04 1

Coolant Bottle Molded Coolant Bottle, 

Molded

Design Profit ®
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2 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$28.80 Tool H Cap, Trans Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Bottle, 200-400 Ton

Molded

$28.80 Part H Cap, Trans H Cap, Trans Coolant Bottle, H Cap, Trans 0.0000 sec 1.7910 sec $0.03 $0.01 1

Coolant Bottle, Material Coolant Bottle, 

Molded Material

- - - Raw Material Req 0.038 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 136mm L x 56mm W x - - - - - -

37mm H

$43.52 Tool H Cap, Trans Stencil 6.0000 sec 6.0000 sec $0.00 $0.07 1

Coolant Bottle

$43.52 Fastening H Cap, Trans Apply Paint 15.0000 sec 15.0000 sec $0.00 $0.18 1

Coolant Bottle

$43.52 Multitouch H Bottle Asm, Grab & Position Cap Retainer Grab & Position 9.0000 sec 9.0000 sec $0.00 $0.11 1

Trans Coolant Cap Retainer

$43.52 Fastening H Bottle Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

Trans Coolant

$43.52 Part H Bottle Asm, H Label, Trans Cooler Bottle H Label, Trans 9.0000 sec 9.0000 sec $0.10 $0.11 1

Trans Coolant Cooler Bottle

$43.52 Fastening Fastening H Bottle Asm, H Bottle Asm, Apply Label Apply Label 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.04 1

Trans Coolant

$54.35 Subassembly H Bottle Asm H Hose Asm, Coolant, Trans to H Hose Asm, 6.0000 sec 6.0000 sec - $0.07 1

w/Hose, Trans Bottle Coolant, Trans to 

Coolant Bottle

$54.35 Tool H Hose Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant, Trans to 

Bottle

$35.94 P.-P. Part H Hose Asm, H Hose, Coolant, Trans to Bottle, H Hose, Coolant, 3.0000 sec 3.0000 sec - $0.05 1

Coolant, Trans to Extruded Trans to Bottle, 

Bottle Extruded

$35.94 Tool H Hose, Coolant, Extruder 32mm Base 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans to Bottle, 

Extruded

$35.94 Part H Hose, Coolant, H Hose, Coolant, Trans to Bottle, H Hose, Coolant, 0.0000 sec 3.7659 sec $0.15 $0.04 1

Trans to Bottle, Material Trans to Bottle, 

Extruded Material

- - - Box Size 175mmL x 66mmW x - - - - - -

29mmH

Design Profit ®
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3 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Part H Hose Asm, H Sheath, (15/16"), Bottle to H Sheath, 6.0000 sec 6.0000 sec $0.18 $0.09 1

Coolant, Trans to Trans Hose (15/16"), Bottle to 

Bottle Trans Hose

$54.35 Part H Hose Asm, H Hose Clamp, Medium (24mm) H Hose Clamp, 7.0000 sec 7.0000 sec $0.22 $0.11 1

Coolant, Trans to Medium (24mm)

Bottle

$54.35 Part H Hose Asm, H Hose Clamp, Medium (22mm) H Hose Clamp, 7.0000 sec 7.0000 sec $0.21 $0.11 1

Coolant, Trans to Medium (22mm)

Bottle

$54.35 Tool H Hose Asm, Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.05 1

Coolant, Trans to 

Bottle

$54.35 Fastening H Hose Asm, Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.03 2

Coolant, Trans to 

Bottle

$54.35 Operation H Hose Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Coolant, Trans to 

Bottle

$43.52 Operation H Bottle Asm Press part 3.0000 sec 3.0000 sec $0.00 $0.04 1

w/Hose, Trans 

Coolant

$43.52 Tool H Bottle Asm H Bottle Asm Hand Tool Hand Tool 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.04 1

w/Hose, Trans 

Coolant

$43.52 Fastening H Bottle Asm Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.02 1

w/Hose, Trans 

Coolant

$83.31 Part H Trans & DC-DC H Bolt Trans Coolant Bottle H Bolt Trans 4.0000 sec 4.0000 sec $0.06 $0.09 1

Cooling System Coolant Bottle

$83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Operation H Trans & DC-DC CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Cooling System

$83.31 Part H Trans & DC-DC H Nut Trans Coolant Bottle H Nut Trans 4.0000 sec 4.0000 sec $0.06 $0.09 1

Cooling System Coolant Bottle

$83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

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4 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$83.31 Multitouch H Trans & DC-DC H Hose Coolant Bottle to Trans H Hose Coolant 6.0000 sec 6.0000 sec $0.00 $0.14 1

Cooling System Bottle to Trans

$83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.05 1

Cooling System

$83.31 Operation H Trans & DC-DC CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Cooling System

- - - Install Trans Coolant Pump Sub - - - - - -

$35.51 Subassembly H Trans & DC-DC H Trans Coolant Pump Sub Asm H Trans Coolant 9.0000 sec 9.0000 sec - $0.21 1

Cooling System Pump Sub Asm

$35.51 Tool H Trans Coolant First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump Sub Asm

$35.51 Subassembly H Trans Coolant H Trans Coolant Pump w/Mount H Trans Coolant 3.0000 sec 3.0000 sec - $0.03 1

Pump Sub Asm Pump w/Mount

$35.51 Tool H Trans Coolant First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump w/Mount

$29.69 Subassembly H Trans Coolant H Trans Coolant Pump H Trans Coolant 3.0000 sec 3.0000 sec $0.00 $0.03 1

Pump w/Mount Pump

$16.39 P.-P. Part P.-P. Part H Trans Coolant H Trans Coolant H Isolation Ring, Mount, Coolant H Isolation Ring, Mount, Coolant H Isolation Ring, H Isolation Ring, 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec - $0.06 1

Pump w/Mount Pump Mount, Coolant 

Pump

$16.39 Tool H Isolation Ring, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Mount, Coolant ton

Pump

$16.39 Part H Isolation Ring, H Isolation Ring, Mount, Coolant H Isolation Ring, 0.0000 sec 3.2560 sec $0.05 $0.01 1

Mount, Coolant Pump, Material Mount, Coolant 

Pump Pump, Material

- - - Raw Material Req 0.049 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 60mm L x 60mm W x - - - - - -

23mm H

$35.51 Fastening H Trans Coolant Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump w/Mount

$16.39 P.-P. Part H Trans Coolant H Clamp, Mount, Coolant Pump H Clamp, Mount, 8.0000 sec 8.0000 sec - $0.08 1

Pump w/Mount Coolant Pump

$16.39 Tool H Clamp, Mount, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Pump ton
Design Profit

®

Page 5 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$16.39 Part H Clamp, Mount, H Clamp, Mount, Coolant Pump, H Clamp, Mount, 0.0000 sec 1.1810 sec $0.08 $0.01 1

Coolant Pump Material Coolant Pump, 

Material

- - - Raw Material Req 0.043 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 100mm L x 73mm W x - - - - - -

24mm H

$35.51 Fastening H Trans Coolant Position Clamp 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump w/Mount

$35.51 Fastening H Trans Coolant Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump w/Mount

$35.51 Operation H Trans Coolant CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump w/Mount

$35.51 Subassembly H Trans Coolant H Bracket Asm, Mount, Coolant H Bracket Asm, 6.0000 sec 6.0000 sec - $0.06 1

Pump w/Mount Pump Mount, Coolant 

Pump

$35.51 Tool H Bracket Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Mount, Coolant 

Pump

$55.17 P.-P. Part H Bracket Asm, H Bracket, Mount, Coolant Pump H Bracket, Mount, 3.0000 sec 3.0000 sec - $0.03 1

Mount, Coolant Coolant Pump

Pump

$55.17 Tool H Bracket, Mount, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Pump

- - - E-coat - - - - - -

$10.75 P.-P. Part H Bracket, Mount, H Bracket, Mount, Coolant Pump, H Bracket, Mount, 3.0000 sec 3.0000 sec - $0.05 1

Coolant Pump Washed Coolant Pump, 

Washed

$10.75 Tool H Bracket, Mount, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Pump, DRY

Washed

$15.50 P.-P. Part H Bracket, Mount, H Bracket, Mount, Coolant Pump, H Bracket, Mount, 3.0000 sec 3.0000 sec - $0.01 1

Coolant Pump, Stamped Coolant Pump, 

Washed Stamped

$15.50 Tool H Bracket, Mount, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Pump, 

Stamped

$15.50 Part H Bracket, Mount, H Bracket, Mount, Coolant Pump, H Bracket, Mount, 0.0000 sec 0.7000 sec $0.14 $0.00 1

Coolant Pump, Material Coolant Pump, 

Stamped Material

- - - Blank weight 0.303 lbs - - - - - -

Design Profit ®
Page 

6 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - 60 Ton Progressive Press - - - - - -

- - - Part Size after stamping (92 L by - - - - - -

87 W by 15 H)mm

$10.75 Operation H Bracket, Mount, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Coolant Pump, 

Washed

$10.75 Operation H Bracket, Mount, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Coolant Pump, 

Washed

$10.75 Operation H Bracket, Mount, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Coolant Pump, 

Washed

$55.17 Operation H Bracket, Mount, Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Coolant Pump

$55.17 Operation H Bracket, Mount, Paint Part Small 3.0000 sec 3.0000 sec $0.00 $0.05 1

Coolant Pump

$55.17 Tool H Bracket, Mount, Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coolant Pump

$55.17 Operation H Bracket, Mount, Paint Oven Cure 60.0000 sec 60.0000 sec $0.00 $0.92 1

Coolant Pump

$55.17 Operation H Bracket, Mount, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Coolant Pump

$35.51 Part H Bracket Asm, H Foam Pad, Self Stick, Pump H Foam Pad, Self 7.0000 sec 7.0000 sec $0.01 $0.07 1

Mount, Coolant Bracket Stick, Pump 

Pump Bracket

$35.51 Fastening H Bracket Asm, Apply Label 3.0000 sec 3.0000 sec $0.00 $0.03 1

Mount, Coolant 

Pump

$35.51 Fastening H Trans Coolant Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump w/Mount

$54.35 Subassembly H Trans Coolant H Coolant Line Asm, Pump to E H Coolant Line 9.0000 sec 9.0000 sec - $0.09 1

Pump Sub Asm Motor Asm, Pump to E 

Motor

$54.35 Tool H Coolant Line First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Pump to E 

Motor

$35.94 P.-P. Part H Coolant Line H Coolant Line, Pump to E Motor H Coolant Line, 4.0000 sec 4.0000 sec - $0.06 1

Asm, Pump to E Pump to E Motor

Motor

$35.94 Tool H Coolant Line, Extruder 32mm Base 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump to E Motor

Design Profit ®
Page 

7 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.94 Part H Coolant Line, H Coolant Line, Pump to E Motor, H Coolant Line, 0.0000 sec 6.9240 sec $0.37 $0.07 1

Pump to E Motor Material Pump to E Motor, 

Material

- - - Box Size 230mmL x 118mmW x - - - - - -

86mmH

$54.35 Part H Coolant Line H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec 7.0000 sec $0.23 $0.11 2

Asm, Pump to E Medium (27mm)

Motor

$54.35 Tool H Coolant Line Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.05 1

Asm, Pump to E 

Motor

$54.35 Fastening H Coolant Line Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.03 2

Asm, Pump to E 

Motor

$54.35 Operation H Coolant Line CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Asm, Pump to E 

Motor

$35.51 Operation H Trans Coolant Press part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Pump Sub Asm

$35.51 Tool H Trans Coolant Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.03 1

Pump Sub Asm

$35.51 Fastening Fastening H Trans Coolant H Trans Coolant Relase Hose Spring Clamp Relase Hose Spring Clamp 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump Sub Asm

$35.51 Operation H Trans Coolant CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump Sub Asm

$54.35 Subassembly H Trans Coolant H Coolant Line Asm, DC-DC to H Coolant Line 9.0000 sec 9.0000 sec - $0.09 1

Pump Sub Asm Pump Asm, DC-DC to 

Pump

$54.35 Tool H Coolant Line First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, DC-DC to 

Pump

$35.94 P.-P. Part H Coolant Line H Coolant Line, DC-DC to Pump H Coolant Line, 4.0000 sec 4.0000 sec - $0.06 1

Asm, DC-DC to DC-DC to Pump

Pump

$35.94 Tool H Coolant Line, Extruder 32mm Base 0.0000 sec 0.0000 sec $0.00 $0.00 1

DC-DC to Pump

$35.94 Part H Coolant Line, H Coolant Line, DC-DC to Pump, H Coolant Line, 0.0000 sec 15.9679 sec $0.55 $0.16 1

DC-DC to Pump Material DC-DC to Pump, 

Material

- - - Box Size 520mmL x 280mmW x - - - - - -

115mmH

Design Profit ®
Page 

8 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Part H Coolant Line H Sheath, (15/16"), Pump to H Sheath, 7.0000 sec 7.0000 sec $1.19 $0.11 1

Asm, DC-DC to Dc-Dc Module (15/16"), Pump to 

Pump Dc-Dc Module

$54.35 Part H Coolant Line H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec 7.0000 sec $0.23 $0.11 2

Asm, DC-DC to Medium (27mm)

Pump

$54.35 Tool H Coolant Line Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.05 1

Asm, DC-DC to 

Pump

$54.35 Fastening H Coolant Line Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.03 2

Asm, DC-DC to 

Pump

$54.35 Operation H Coolant Line CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Asm, DC-DC to 

Pump

$54.35 Part H Coolant Line H Strap On Hose Clip (#7) H Strap On Hose 11.0000 sec 11.0000 sec $0.04 $0.17 1

Asm, DC-DC to Clip (#7)

Pump

$54.35 Fastening H Coolant Line Zip Tie 3.0000 sec 3.0000 sec $0.00 $0.05 1

Asm, DC-DC to 

Pump

$54.35 Tool H Coolant Line H Coolant Line Hand Tool Hand Tool 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.05 1

Asm, DC-DC to 

Pump

$54.35 Fastening H Coolant Line Trim to Length 1.0000 sec 1.0000 sec $0.00 $0.02 1

Asm, DC-DC to 

Pump

$16.39 P.-P. Part H Coolant Line H Clamp On Christmas Tree Clip H Clamp On 10.0000 sec 10.0000 sec - $0.15 1

Asm, DC-DC to Christmas Tree 

Pump Clip

$16.39 Tool H Clamp On Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Christmas Tree ton

Clip

$16.39 Part H Clamp On H Clamp On Christmas Tree Clip, H Clamp On 0.0000 sec 1.0920 sec $0.05 $0.00 1

Christmas Tree Material Christmas Tree 

Clip Clip, Material

- - - Raw Material Req 0.026 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 77mm L x 45mm W x - - - - - -

20mm H

Design Profit ®
Page 

9 of#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Fastening H Coolant Line Snap Together 1.0000 sec 1.0000 sec $0.00 $0.02 1

Asm, DC-DC to 

Pump

$35.51 Operation H Trans Coolant Press part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Pump Sub Asm

$35.51 Tool H Trans Coolant Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.03 1

Pump Sub Asm

$35.51 Fastening H Trans Coolant Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump Sub Asm

$83.31 Part H Trans & DC-DC H Bolt, Trans Coolant Pump H Bolt, Trans 4.0000 sec 4.0000 sec $0.06 $0.09 2

Cooling System Coolant Pump

$83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 2

Cooling System

$83.31 Multitouch H Trans & DC-DC H Regrab Pump Hose H Regrab Pump 8.0000 sec 8.0000 sec $0.00 $0.19 1

Cooling System Hose

$83.31 Fastening H Trans & DC-DC Press in Xmass Clip 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

- - - Install Hose: Pump to DC-DC - - - - - -

Module

$83.31 Multitouch Multitouch H Trans & DC-DC H Trans & DC-DC H Regrab Pump Hose H Regrab Pump Hose H Regrab Pump H Regrab Pump 8.0000 sec 8.0000 sec 8.0000 sec 8.0000 sec $0.00 $0.19 1

Cooling System Hose

$83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.05 1

Cooling System

- - - Install Hose: Pump to Trans - - - - - -

$83.31 Multitouch H Trans & DC-DC H Regrab Pump Hose H Regrab Trans 8.0000 sec 8.0000 sec $0.00 $0.19 1

Cooling System Hose

$83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.05 1

Cooling System

$83.31 Operation H Trans & DC-DC CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Cooling System

- - - Space for Printing - - - - - -

Design Profit ®

Page 10 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Install Cooler Asm to FEM (Prior - - - - - -

to Radiator Asm)

$35.51 Subassembly H Trans & DC-DC H Cooler Asm, Trans & DC-DC H Cooler Asm, 10.0000 sec 10.0000 sec - $0.23 1

Cooling System Mod Trans & DC-DC 

Mod

$35.51 Tool H Cooler Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans & DC-DC 

Mod

$35.51 Subassembly H Cooler Asm, H Exchanger Asm, Trans Cooler H Exchanger 4.0000 sec 4.0000 sec - $0.04 1

Trans & DC-DC Asm Asm, Trans 

Mod Cooler Asm

$35.51 Tool H Exchanger First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Trans 

Cooler Asm

$55.17 Subassembly Subassembly H Exchanger H Exchanger H Exchanger Asm, Trans Cooler, H Exchanger Asm, Trans Cooler, H Exchanger H Exchanger 4.0000 sec 4.0000 sec 4.0000 sec 4.0000 sec - $0.04 1

Asm, Trans Painted Asm, Trans 

Cooler Asm Cooler, Painted

$55.17 Tool H Exchanger First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Trans 

Cooler, Painted

- - - Spray painted - - - - - -

$49.29 Subassembly H Exchanger H Exchanger Asm, Trans Cooler, H Exchanger 4.0000 sec 4.0000 sec - $0.06 1

Asm, Trans Washed Asm, Trans 

Cooler, Painted Cooler, Washed

$49.29 Tool H Exchanger Washer Med Batch special 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Trans nozzels

Cooler, Washed

$46.52 Subassembly H Exchanger H Exchanger Asm, Trans Cooler, H Exchanger 4.0000 sec 4.0000 sec - $0.05 1

Asm, Trans Brazed Asm, Trans 

Cooler, Washed Cooler, Brazed

$46.52 Tool H Exchanger Furnace/Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Trans 

Cooler, Brazed

Design Profit ®

Page 11 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.18 Subassembly H Exchanger H Exchanger Asm, Assembled H Exchanger 4.0000 sec 4.0000 sec - $0.05 1

Asm, Trans Loose Asm, Assembled 

Cooler, Brazed Loose

$42.18 Tool H Exchanger First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Assembled 

Loose

$42.18 Subassembly H Exchanger H Cooler Core Asm, Exchanger H Cooler Core 4.0000 sec 4.0000 sec - $0.05 1

Asm, Assembled Asm, Exchanger

Loose

$42.18 Tool H Cooler Core First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Exchanger

- - - Stack 17 Tubes & 16 Fins - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool Cut Off Tool 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®
Page 12 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

Design Profit ®
Page 13 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

Design Profit ®

Page 14 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. Material Mod. H Fin, Exchanger H Fin, Exchanger Roll Form Fin Roll Form Fin 0.7969 sec 0.7969 sec 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

Design Profit ®

Page 15 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

Design Profit ®

Page 16 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 17 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. Material Mod. H Tube Debur/Tumble Debur/Tumble 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

Design Profit ®

Page 18 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

Design Profit ®
Page 19 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 20 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

Design Profit ®

Page 21 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment Deburing Equipment 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

Design Profit ®

Page 22 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

Design Profit ®

Page 23 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. Material Mod. H Fin, Exchanger H Fin, Exchanger Roll Form Fin Roll Form Fin 0.7969 sec 0.7969 sec 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

Design Profit ®

Page 24 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

Design Profit ®

Page 25 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 26 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. Material Mod. H Tube Debur/Tumble Debur/Tumble 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

Design Profit ®

Page 27 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

Design Profit ®
Page 28 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 29 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec 6.0000 sec - $0.07 1

Asm, Exchanger Formed Asm, Roll Formed

$42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Roll Formed

$42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec 0.0000 sec $0.08 $0.00 1

Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock - - - - - -

$42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec 0.7969 sec $0.00 $0.01 1

Asm, Roll Formed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec 3.0000 sec - $0.04 1

Asm, Exchanger Deburred Exchanger Asm, 

Deburred

$54.35 Tool H Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Deburred

$17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec 4.0000 sec - $0.06 1

Exchanger Asm, Extruded Exchanger Asm, 

Deburred Extruded

$17.08 Tool H Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm, 

Extruded

$17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec 0.0000 sec $0.76 $0.00 1

Exchanger Asm, Exchanger Asm, 

Extruded Material

$17.08 Material Mod. H Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger Asm, 

Extruded

$54.35 Operation H Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm, 

Deburred

$54.35 Operation H Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm, 

Deburred

$42.18 Operation H Cooler Core Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 2

Asm, Exchanger

Design Profit ®
Page 30 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.18 Operation H Exchanger Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 2

Asm, Assembled 

Loose

$42.18 Subassembly H Exchanger H LH Outboard Tank, Exchanger H LH Outboard 3.0000 sec 3.0000 sec - $0.04 1

Asm, Assembled Tank, Exchanger

Loose

$42.18 Tool H LH Outboard First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Tank, Exchanger

$15.50 P.-P. Part H LH Outboard H LH Outboard Tank, Exchanger, H LH Outboard 3.0000 sec 3.0000 sec - $0.04 1

Tank, Exchanger Stamped Tank, Exchanger, 

Stamped

$15.50 Tool H LH Outboard Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Tank, Exchanger, 

Stamped

$15.50 Part H LH Outboard H LH Outboard Tank, Exchanger, H LH Outboard 0.0000 sec 0.7000 sec $0.16 $0.00 1

Tank, Exchanger, Material Tank, Exchanger, 

Stamped Material

- - - Blank weight 0.069 lbs - - - - - -

- - - Press Size 60 Ton Prog - - - - - -

- - - Part Size after stamping (205 L - - - - - -

by 22 W by 12 H)mm

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$15.50 P.-P. Part H LH Outboard H Tank Endcap, Exchanger H Tank Endcap, 8.0000 sec 8.0000 sec - $0.09 2

Tank, Exchanger Exchanger

$15.50 Tool H Tank Endcap, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 2

Exchanger

$15.50 Part H Tank Endcap, H Tank Endcap, Exchanger, H Tank Endcap, 0.0000 sec 0.6000 sec $0.03 $0.00 2

Exchanger Material Exchanger, 

Material

- - - Blank weight 0.011 lbs - - - - - -

- - - Press Size 25 Ton Prog - - - - - -

- - - Part Size after stamping (24 L by - - - - - -

21 W by 3 H)mm

$42.18 Fastening H LH Outboard Insert Tab in Slot 2.0000 sec 2.0000 sec $0.00 $0.02 2

Tank, Exchanger

- - - Space for Printing - - - - - -

Design Profit ®

Page 31 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.91 P.-P. Part H LH Outboard H Inboard Tank, Exchanger, H Inboard Tank, 8.0000 sec 8.0000 sec - $0.09 1

Tank, Exchanger Stamping Exchanger, 

Stamping

$42.91 Tool H Inboard Tank, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger, 

Stamping

$42.91 Part H Inboard Tank, H Inboard Tank, Exchanger, H Inboard Tank, 0.0000 sec 1.8000 sec $0.16 $0.02 1

Exchanger, Material Exchanger, 

Stamping Material

- - - Blank weight 0.069 lbs - - - - - -

- - - Press Size 300 Ton Prog - - - - - -

- - - Part Size after stamping (205 L - - - - - -

by 24 W by 16 H)mm

$42.18 Tool H LH Outboard Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.04 1

Tank, Exchanger

$42.18 Fastening H LH Outboard Peen In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Tank, Exchanger

$42.18 Operation H LH Outboard Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Tank, Exchanger

$42.18 Fastening H LH Outboard Peen In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Tank, Exchanger

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H LH Outboard H Return Tube, Exchanger Asm H Return Tube, 5.0000 sec 5.0000 sec - $0.06 1

Tank, Exchanger Exchanger Asm

$54.35 Tool H Return Tube, Tube Cutter 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm

- - - Start with Tube Stock - - - - - -

$54.35 P.-P. Part H Return Tube, H Return Tube, Exchanger, H Return Tube, 0.0000 sec 0.0000 sec $0.08 $0.00 1

Exchanger Asm Material Exchanger, 

Material

- - - Weight before machining 0.0361 - - - - - -

lbs

$54.35 Operation H Return Tube, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm

$54.35 Material Mod. H Return Tube, Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

Design Profit ®
Page 32 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Tool H Return Tube, Tube Bending Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger Asm

$54.35 Operation H Return Tube, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm

$54.35 Material Mod. H Return Tube, Crimp Tube 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm

$54.35 Material Mod. H Return Tube, Bend Tube 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm

$54.35 Operation H Return Tube, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm

$54.35 Material Mod. H Return Tube, Crimp Tube 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger Asm

$54.35 Material Mod. H Return Tube, Flare Tube End 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$54.35 Operation H Return Tube, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.08 1

Exchanger Asm

$54.35 Material Mod. H Return Tube, Flare Tube End - Double 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger Asm

$54.35 Operation H Return Tube, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.02 1

Exchanger Asm

$42.18 Fastening H LH Outboard Push Tube in place 3.0000 sec 3.0000 sec $0.00 $0.04 1

Tank, Exchanger

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®
Page 33 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 34 of #

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$37.60 P.-P. Part H Exchanger H LH Mounting Bracket, H LH Mounting 5.0000 sec 5.0000 sec - $0.06 1

Asm, Assembled Exchanger, Deburred Bracket, 

Loose Exchanger, 

Deburred

$37.60 Tool H LH Mounting Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket, 

Exchanger, 

Deburred

$31.33 P.-P. Part H LH Mounting H LH Mounting Bracket, H LH Mounting 3.0000 sec 3.0000 sec - $0.03 1

Bracket, Exchanger, Machined Bracket, 

Exchanger, Exchanger, 

Deburred Machined

$31.33 Tool H LH Mounting EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket, Machine

Exchanger, 

Machined

$17.08 P.-P. Part H LH Mounting H LH Mounting Bracket, H LH Mounting 3.0000 sec 3.0000 sec - $0.03 1

Bracket, Exchanger, Extruded Bracket, 

Exchanger, Exchanger, 

Machined Extruded

$17.08 Tool H LH Mounting Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket, 

Exchanger, 

Extruded

$17.08 Part H LH Mounting H LH Mounting Bracket, H LH Mounting 0.0000 sec 0.0000 sec $0.13 $0.00 1

Bracket, Exchanger, Material Bracket, 

Exchanger, Exchanger, 

Extruded Material

$17.08 Material Mod. H LH Mounting Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Bracket, 

Exchanger, 

Extruded

$31.33 Operation H LH Mounting Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Machined

$31.33 Operation H LH Mounting Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Machined

Design Profit ®
Page 35 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Bore hole - - - - - -

$31.33 Material Mod. H LH Mounting Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Bracket, 

Exchanger, 

Machined

$31.33 Operation H LH Mounting Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Bracket, 

Exchanger, 

Machined

$31.33 Operation H LH Mounting Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Bracket, 

Exchanger, 

Machined

$37.60 Operation H LH Mounting Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Deburred

$37.60 Material Mod. H LH Mounting Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Deburred

$37.60 Operation H LH Mounting Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Bracket, 

Exchanger, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Exchanger H Locator Bracket, Exchanger, H Locator Bracket, 5.0000 sec 5.0000 sec - $0.06 1

Asm, Assembled Deburred Exchanger, 

Loose Deburred

$54.35 Tool H Locator Bracket, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger, 

Deburred

Design Profit ®
Page 36 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$17.08 P.-P. Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 3.0000 sec 3.0000 sec - $0.05 1

Exchanger, Extruded Exchanger, 

Deburred Extruded

$17.08 Tool H Locator Bracket, Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger, 

Extruded

$17.08 Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 0.0000 sec 0.0000 sec $0.13 $0.00 1

Exchanger, Material Exchanger, 

Extruded Material

$17.08 Material Mod. H Locator Bracket, Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger, 

Extruded

$54.35 Operation H Locator Bracket, Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger, 

Deburred

$54.35 Material Mod. H Locator Bracket, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger, 

Deburred

$54.35 Operation H Locator Bracket, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger, 

Deburred

$42.18 Operation Operation H Exchanger H Exchanger Clamp Part Clamp Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.04 2

Asm, Assembled 

Loose

$42.18 Operation H Exchanger 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Assembled 

Loose

$42.18 Operation H Exchanger CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Assembled 

Loose

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 Subassembly H Exchanger H RH Outboard Tank, Exchanger H RH Outboard 8.0000 sec 8.0000 sec - $0.09 1

Asm, Assembled Tank, Exchanger

Loose

$42.18 Tool H RH Outboard First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Tank, Exchanger

$42.91 P.-P. Part H RH Outboard H Inboard Tank, Exchanger, H Inboard Tank, 3.0000 sec 3.0000 sec - $0.04 1

Tank, Exchanger Stamping Exchanger, 

Stamping

Design Profit ®
Page 37 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.91 Tool H Inboard Tank, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger, 

Stamping

$42.91 Part H Inboard Tank, H Inboard Tank, Exchanger, H Inboard Tank, 0.0000 sec 1.8000 sec $0.16 $0.02 1

Exchanger, Material Exchanger, 

Stamping Material

- - - Blank weight 0.069 lbs - - - - - -

- - - Press Size 300 Ton Prog - - - - - -

- - - Part Size after stamping (205 L - - - - - -

by 24 W by 16 H)mm

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$15.50 P.-P. Part H RH Outboard H Tank Endcap, Exchanger H Tank Endcap, 8.0000 sec 8.0000 sec - $0.09 2

Tank, Exchanger Exchanger

$15.50 Tool H Tank Endcap, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 2

Exchanger

$15.50 Part H Tank Endcap, H Tank Endcap, Exchanger, H Tank Endcap, 0.0000 sec 0.6000 sec $0.03 $0.00 2

Exchanger Material Exchanger, 

Material

- - - Blank weight 0.011 lbs - - - - - -

- - - Press Size 25 Ton Prog - - - - - -

- - - Part Size after stamping (24 L by - - - - - -

21 W by 3 H)mm

$42.18 Fastening H RH Outboard Insert Tab in Slot 2.0000 sec 2.0000 sec $0.00 $0.02 2

Tank, Exchanger

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$15.50 P.-P. Part H RH Outboard H RH Outboard Tank, Exchanger, H RH Outboard 8.0000 sec 8.0000 sec - $0.09 1

Tank, Exchanger Stamped Tank, Exchanger, 

Stamped

$15.50 Tool H RH Outboard Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Tank, Exchanger, 

Stamped

Design Profit ®
Page 38 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$15.50 Part H RH Outboard H RH Outboard Tank, Exchanger, H RH Outboard 0.0000 sec 0.7000 sec $0.16 $0.00 1

Tank, Exchanger, Material Tank, Exchanger, 

Stamped Material

- - - Blank weight 0.069 lbs - - - - - -

- - - Press Size 60 Ton Prog - - - - - -

- - - Part Size after stamping (205 L - - - - - -

by 22 W by 12 H)mm

$42.18 Tool H RH Outboard Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.04 1

Tank, Exchanger

$42.18 Fastening H RH Outboard Peen In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Tank, Exchanger

$42.18 Operation H RH Outboard Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Tank, Exchanger

$42.18 Fastening H RH Outboard Peen In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Tank, Exchanger

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$37.60 P.-P. Part H Exchanger H Fluid Pipe Fitting Exchanger H Fluid Pipe 5.0000 sec 5.0000 sec - $0.06 1

Asm, Assembled Asm, Extruded Fitting Exchanger 

Loose Asm, Extruded

Design Profit ®

Page 39 of #

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$37.60 Tool H Fluid Pipe Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Fitting Exchanger 

Asm, Extruded

$31.33 P.-P. Part H Fluid Pipe H Fluid Pipe Fitting Exchanger H Fluid Pipe 3.0000 sec 3.0000 sec - $0.03 1

Fitting Exchanger Asm, Machined Fitting Exchanger 

Asm, Extruded Asm, Machined

$31.33 Tool H Fluid Pipe EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Fitting Exchanger Machine

Asm, Machined

$17.08 P.-P. Part H Fluid Pipe H Fluid Pipe Fitting Exchanger H Fluid Pipe 3.0000 sec 3.0000 sec - $0.03 1

Fitting Exchanger Asm, Extruded Fitting Exchanger 

Asm, Machined Asm, Machined-1

$17.08 Tool H Fluid Pipe Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Fitting Exchanger 

Asm, Extruded

$17.08 Part H Fluid Pipe H Fluid Pipe Fitting Exchanger H Fluid Pipe 0.0000 sec 0.0000 sec $0.30 $0.00 1

Fitting Exchanger Asm, Material Fitting Exchanger 

Asm, Extruded Asm, Material

$17.08 Material Mod. H Fluid Pipe Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Fitting Exchanger 

Asm, Extruded

$31.33 Operation Operation H Fluid Pipe H Fluid Pipe Load Part Load Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.03 1

Fitting Exchanger 

Asm, Machined

$31.33 Operation H Fluid Pipe Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Fitting Exchanger 

Asm, Machined

- - - Mill face - - - - - -

$31.33 Material Mod. H Fluid Pipe Milled face 1.0000 sec 1.0000 sec $0.00 $0.01 1

Fitting Exchanger 

Asm, Machined

$31.33 Operation H Fluid Pipe Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Fitting Exchanger 

Asm, Machined

- - - Bore and tap hole - - - - - -

$31.33 Material Mod. H Fluid Pipe Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec $0.00 $0.04 1

Fitting Exchanger 

Asm, Machined

$31.33 Operation H Fluid Pipe Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Fitting Exchanger 

Asm, Machined

- - - Bore inner hole - - - - - -

Design Profit ®
Page 40 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$31.33 Material Mod. H Fluid Pipe Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Fitting Exchanger 

Asm, Machined

$31.33 Operation H Fluid Pipe Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Fitting Exchanger 

Asm, Machined

- - - Bore and chamfer outer hole - - - - - -

$31.33 Material Mod. H Fluid Pipe Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Fitting Exchanger 

Asm, Machined

$31.33 Operation H Fluid Pipe Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Fitting Exchanger 

Asm, Machined

$31.33 Operation H Fluid Pipe Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Fitting Exchanger 

Asm, Machined

$37.60 Operation H Fluid Pipe Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Fitting Exchanger 

Asm, Extruded

$37.60 Material Mod. H Fluid Pipe Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.03 1

Fitting Exchanger 

Asm, Extruded

$37.60 Operation H Fluid Pipe Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Fitting Exchanger 

Asm, Extruded

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 41 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$37.60 P.-P. Part H Exchanger H RH Mounting Bracket, H RH Mounting 5.0000 sec 5.0000 sec - $0.06 1

Asm, Assembled Exchanger, Deburred Bracket, 

Loose Exchanger, 

Deburred

$37.60 Tool H RH Mounting Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket, 

Exchanger, 

Deburred

$31.33 P.-P. Part H RH Mounting H RH Mounting Bracket, H RH Mounting 3.0000 sec 3.0000 sec - $0.03 1

Bracket, Exchanger, Machined Bracket, 

Exchanger, Exchanger, 

Deburred Machined

$31.33 Tool H RH Mounting EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket, Machine

Exchanger, 

Machined

$17.08 P.-P. Part H RH Mounting H RH Mounting Bracket, H RH Mounting 3.0000 sec 3.0000 sec - $0.03 1

Bracket, Exchanger, Extruded Bracket, 

Exchanger, Exchanger, 

Machined Extruded

$17.08 Tool H RH Mounting Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket, 

Exchanger, 

Extruded

$17.08 Part H RH Mounting H RH Mounting Bracket, H RH Mounting 0.0000 sec 0.0000 sec $0.13 $0.00 1

Bracket, Exchanger, Material Bracket, 

Exchanger, Exchanger, 

Extruded Material

$17.08 Material Mod. H RH Mounting Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Bracket, 

Exchanger, 

Extruded

$31.33 Operation H RH Mounting Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Machined

$31.33 Operation H RH Mounting Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Machined

- - - Bore hole - - - - - -

Design Profit ®
Page 42 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$31.33 Material Mod. H RH Mounting Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Bracket, 

Exchanger, 

Machined

$31.33 Operation H RH Mounting Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Bracket, 

Exchanger, 

Machined

$31.33 Operation H RH Mounting Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Bracket, 

Exchanger, 

Machined

$37.60 Operation H RH Mounting Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Deburred

$37.60 Material Mod. H RH Mounting Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.03 1

Bracket, 

Exchanger, 

Deburred

$37.60 Operation H RH Mounting Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Bracket, 

Exchanger, 

Deburred

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$54.35 P.-P. Part H Exchanger H Locator Bracket, Exchanger, H Locator Bracket, 5.0000 sec 5.0000 sec - $0.06 1

Asm, Assembled Deburred Exchanger, 

Loose Deburred

$54.35 Tool H Locator Bracket, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger, 

Deburred

$17.08 P.-P. Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 3.0000 sec 3.0000 sec - $0.05 1

Exchanger, Extruded Exchanger, 

Deburred Extruded

Design Profit ®
Page 43 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$17.08 Tool H Locator Bracket, Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Exchanger, 

Extruded

$17.08 Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 0.0000 sec 0.0000 sec $0.13 $0.00 1

Exchanger, Material Exchanger, 

Extruded Material

$17.08 Material Mod. H Locator Bracket, Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.02 1

Exchanger, 

Extruded

$54.35 Operation H Locator Bracket, Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger, 

Deburred

$54.35 Material Mod. H Locator Bracket, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.05 1

Exchanger, 

Deburred

$54.35 Operation H Locator Bracket, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Exchanger, 

Deburred

$42.18 Operation H Exchanger Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 3

Asm, Assembled 

Loose

$46.52 Operation Operation H Exchanger H Exchanger Load Part Load Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm, Trans 

Cooler, Brazed

$46.52 Material Mod. H Exchanger Oven Braze large part 20.0000 sec 20.0000 sec $0.00 $0.26 1

Asm, Trans 

Cooler, Brazed

$46.52 Operation H Exchanger Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler, Brazed

$49.29 Operation H Exchanger Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm, Trans 

Cooler, Washed

$49.29 Operation H Exchanger Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.07 1

Asm, Trans 

Cooler, Washed

$49.29 Operation H Exchanger Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler, Washed

$55.17 Operation H Exchanger Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Asm, Trans 

Cooler, Painted

Design Profit ®
Page 44 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$55.17 Operation H Exchanger Paint Part Medium 5.0000 sec 5.0000 sec $0.00 $0.08 1

Asm, Trans 

Cooler, Painted

$55.17 Operation H Exchanger Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler, Painted

$35.51 Part H Exchanger H Label, Exchanger Asm H Label, 10.0000 sec 10.0000 sec $0.10 $0.10 1

Asm, Trans Exchanger Asm

Cooler Asm

$35.51 Fastening H Exchanger Apply Label 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler Asm

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 45 of #

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 46 of #

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$35.51 Subassembly H Cooler Asm, H Tube & Hose Asm, Trans H Tube & Hose 9.0000 sec 9.0000 sec - $0.09 1

Trans & DC-DC Cooler Asm Asm, Trans 

Mod Cooler Asm

$35.51 Tool H Tube & Hose First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Trans 

Cooler Asm

$54.35 Subassembly H Tube & Hose H Tube Asm, Trans Cooler Asm H Tube Asm, 3.0000 sec 3.0000 sec - $0.03 1

Asm, Trans Trans Cooler Asm

Cooler Asm

Design Profit ®

Page 47 of #

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Tool H Tube Asm, Furnace/Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans Cooler Asm

$54.35 Subassembly H Tube Asm, H Tube Asm, Trans Cooler Asm, H Tube Asm, 3.0000 sec 3.0000 sec - $0.05 1

Trans Cooler Asm Pressed Trans Cooler 

Asm, Pressed

$54.35 Tool H Tube Asm, Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans Cooler 

Asm, Pressed

$44.85 P.-P. Part H Tube Asm, H Pipe, Tube Asm, Trans Cooler H Pipe, Tube 3.0000 sec 3.0000 sec - $0.05 1

Trans Cooler Asm, Trans 

Asm, Pressed Cooler

$44.85 Tool H Pipe, Tube Tube Cutter 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Trans 

Cooler

$44.85 Part H Pipe, Tube H Pipe, Tube Asm, Trans Cooler, H Pipe, Tube 0.0000 sec 0.0000 sec $0.13 $0.00 1

Asm, Trans Material Asm, Trans 

Cooler Cooler, Material

- - - Start with Tube Stock - - - - - -

- - - Weight before machining 0.1026 - - - - - -

lbs

$44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm, Trans 

Cooler

$44.85 Material Mod. H Pipe, Tube Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

$44.85 Tool H Pipe, Tube Tube Bending Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm, Trans 

Cooler

$44.85 Material Mod. H Pipe, Tube Bend Tube 1.0000 sec 1.0000 sec $0.00 $0.01 2

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

Design Profit ®
Page 48 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm, Trans 

Cooler

$44.85 Material Mod. H Pipe, Tube Crimp Tube 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm, Trans 

Cooler

$44.85 Material Mod. Material Mod. H Pipe, Tube H Pipe, Tube Flare Tube End Flare Tube End 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Asm, Trans 

Cooler

$44.85 Material Mod. H Pipe, Tube Flare Tube End - Double 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Trans 

Cooler

$44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 49 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$10.75 P.-P. Part H Tube Asm, H Fitting, Tube Asm, Washed H Fitting, Tube 5.0000 sec 5.0000 sec - $0.08 1

Trans Cooler Asm, Washed

Asm, Pressed

$10.75 Tool H Fitting, Tube Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Washed DRY

$37.60 P.-P. Part H Fitting, Tube H Fitting, Tube Asm, Deburred H Fitting, Tube 3.0000 sec 3.0000 sec - $0.01 1

Asm, Washed Asm, Deburred

$37.60 Tool H Fitting, Tube Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Deburred

$31.33 P.-P. Part H Fitting, Tube H Fitting, Tube Asm, Machined H Fitting, Tube 3.0000 sec 3.0000 sec - $0.03 1

Asm, Deburred Asm, Machined

$31.33 Tool H Fitting, Tube EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Machined Machine

$54.35 P.-P. Part H Fitting, Tube H Fitting, Tube Asm, Extruded H Fitting, Tube 3.0000 sec 3.0000 sec - $0.03 1

Asm, Machined Asm, Extruded

$54.35 Tool H Fitting, Tube Extrusion Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Extruded

$54.35 Part H Fitting, Tube H Fitting, Tube Asm, Material H Fitting, Tube 0.0000 sec 2.4500 sec $0.57 $0.04 1

Asm, Extruded Asm, Material

- - - Assumed a 0.0594 lb Extrusion - - - - - -

Before Machining

$54.35 Tool H Fitting, Tube Cut Off Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Extruded

Design Profit ®

Page 50 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Material Mod. H Fitting, Tube Cut to Length 4.0000 sec 4.0000 sec $0.00 $0.06 1

Asm, Extruded

$31.33 Operation H Fitting, Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Machined

$31.33 Operation H Fitting, Tube Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Machined

- - - Machine Rear Face & Chamfer - - - - - -

Bolt Hole

$31.33 Material Mod. H Fitting, Tube Mill Flat Med 4.0000 sec 4.0000 sec $0.00 $0.03 1

Asm, Machined

$31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

- - - Machine Tube Bore - - - - - -

$31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

$31.33 Operation H Fitting, Tube CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

- - - Machine Fitting Bore & Chamfer Machine Fitting Bore & Chamfer - - - - - -

$31.33 Material Mod. H Fitting, Tube Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

$31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

- - - Turn Face, Fitting & O-ring Land - - - - - -

$31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Mill Flat Med 4.0000 sec 4.0000 sec $0.00 $0.03 1

Asm, Machined

$31.33 Operation H Fitting, Tube Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

$31.33 Operation H Fitting, Tube Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Turn OD Contoured surface fins 5.0000 sec 5.0000 sec $0.00 $0.04 1

Asm, Machined

Design Profit ®
Page 51 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Cut Groove sml 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Machined

- - - Chamfer Bolt Bore - - - - - -

$31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Asm, Machined

$31.33 Material Mod. H Fitting, Tube Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

$31.33 Operation H Fitting, Tube Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Machined

$31.33 Operation H Fitting, Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Machined

$37.60 Operation H Fitting, Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Deburred

$37.60 Material Mod. H Fitting, Tube Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Deburred

$37.60 Operation H Fitting, Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Deburred

$10.75 Operation H Fitting, Tube Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Asm, Washed

$10.75 Operation Operation H Fitting, Tube H Fitting, Tube Wash Part Medium sh Part Medium 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.01 1

Asm, Washed

$10.75 Operation H Fitting, Tube Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Asm, Washed

$54.35 Fastening H Tube Asm, Press Together 3.0000 sec 3.0000 sec $0.00 $0.05 1

Trans Cooler 

Asm, Pressed

$54.35 Operation H Tube Asm, Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Trans Cooler Asm

$54.35 Material Mod. H Tube Asm, Oven Braze 5.0000 sec 5.0000 sec $0.00 $0.08 1

Trans Cooler Asm

$54.35 Operation H Tube Asm, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Trans Cooler Asm

$35.51 Part H Tube & Hose H O-Ring, 18.5 x 2.5 mm H O-Ring, 18.5 x 7.0000 sec 7.0000 sec $0.06 $0.07 1

Asm, Trans 2.5 mm

Cooler Asm

$35.51 Fastening H Tube & Hose Push Seal in Place 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler Asm

Design Profit ®

Page 52 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Operation H Tube & Hose CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler Asm

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$35.94 P.-P. Part H Tube & Hose H Rubber Tube, 17 mm Diam H Rubber Tube, 7.0000 sec 7.0000 sec - $0.07 1

Asm, Trans 17 mm Diam

Cooler Asm

$35.94 Tool H Rubber Tube, Extruder 32mm Base 0.0000 sec 0.0000 sec $0.00 $0.00 1

17 mm Diam

$35.94 Part H Rubber Tube, H Rubber Tube, 17 mm Diam, H Rubber Tube, 0.0000 sec 0.6432 sec $0.01 $0.01 1

17 mm Diam Material 17 mm Diam, 

Material

- - - Box Size 27mmL x 22mmW x - - - - - -

22mmH

$35.51 Fastening H Tube & Hose Push Tube in place 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler Asm

$35.51 Part H Tube & Hose H Heat Shrink Fabric Tube, 21 H Heat Shrink 9.0000 sec 9.0000 sec $0.07 $0.09 1

Asm, Trans mm Diam Fabric Tube, 21 

Cooler Asm mm Diam

Design Profit ®

Page 53 of #
Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Fastening H Tube & Hose Position Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, Trans 

Cooler Asm

$35.51 Tool H Tube & Hose Heat Gun 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Trans 

Cooler Asm

$35.51 Fastening H Tube & Hose Apply Heat Locally 5.0000 sec 5.0000 sec $0.00 $0.05 1

Asm, Trans 

Cooler Asm

$54.35 Subassembly H Tube & Hose H Hose Asm, Trans Cooler H Hose Asm, 9.0000 sec 9.0000 sec - $0.09 1

Asm, Trans Trans Cooler

Cooler Asm

$54.35 Tool H Hose Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans Cooler

$35.94 P.-P. Part H Hose Asm, H Hose Asm, Trans Cooler H Hose, Trans 4.0000 sec 4.0000 sec - $0.06 1

Trans Cooler Cooler

$35.94 Tool H Hose Asm, Extruder 32mm Base 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trans Cooler

$35.94 Part H Hose Asm, H Hose, Trans Cooler, Material H Hose, Trans 0.0000 sec 5.0373 sec $0.25 $0.05 1

Trans Cooler Cooler, Material

- - - Box Size 190mmL x 98mmW x - - - - - -

35mmH

$54.35 Part H Hose Asm, H Oetiker Clamp, Medium H Oetiker Clamp, 7.0000 sec 7.0000 sec $0.00 $0.11 1

Trans Cooler (26.5mm) Medium (26.5mm)

$54.35 Fastening H Hose Asm, Slide into Position 1.0000 sec 1.0000 sec $0.00 $0.02 1

Trans Cooler

$54.35 Operation H Hose Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Trans Cooler

$54.35 Part H Hose Asm, H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec 7.0000 sec $0.23 $0.11 1

Trans Cooler Medium (27mm)

$54.35 Tool H Hose Asm, Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.05 1

Trans Cooler

$54.35 Fastening H Hose Asm, Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.03 1

Trans Cooler

$35.51 Operation H Tube & Hose Press part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler Asm

$35.51 Tool H Tube & Hose Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, Trans 

Cooler Asm

Design Profit ®
Page 54 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Fastening H Tube & Hose Crimp Oetiker Clamp 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, Trans 

Cooler Asm

$35.51 Part H Cooler Asm, H Bolt, Line Asm to Exchanger H Bolt, Line Asm 4.0000 sec 4.0000 sec $0.06 $0.04 1

Trans & DC-DC to Exchanger

Mod

$35.51 Tool H Cooler Asm, Power Tool 4.0000 sec 4.0000 sec $0.00 $0.04 1

Trans & DC-DC 

Mod

$35.51 Fastening H Cooler Asm, Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 1

Trans & DC-DC 

Mod

$83.31 Fastening H Trans & DC-DC Slide into Position 1.0000 sec 1.0000 sec $0.00 $0.02 1

Cooling System

$83.31 Part H Trans & DC-DC H Bolt, Trans Cooler to FEM H Bolt, Trans 4.0000 sec 4.0000 sec $0.06 $0.09 1

Cooling System Cooler to FEM

$83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Operation H Trans & DC-DC 18" Move 2.0000 sec 2.0000 sec $0.00 $0.05 1

Cooling System

$83.31 Fastening H Trans & DC-DC Slide into Position 1.0000 sec 1.0000 sec $0.00 $0.02 1

Cooling System

$83.31 Part H Trans & DC-DC H Bolt, Trans Cooler to FEM H Bolt, Trans 4.0000 sec 4.0000 sec $0.06 $0.09 1

Cooling System Cooler to FEM

$83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

Cooling System

$83.31 Operation H Trans & DC-DC CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Cooling System

- - - Install FEM/Cooler Hose to - - - - - -

DC-DC Module

$83.31 Multitouch H Trans & DC-DC H Regrab Hose, FEM to DC-DC H Regrab Hose, 8.0000 sec 8.0000 sec $0.00 $0.19 1

Cooling System Module FEM to DC-DC 

Module

$83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

Design Profit ®
Page 55 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.05 1

Cooling System

- - - Install Hose, Cooler to Trans - - - - - -

$54.35 Subassembly H Trans & DC-DC H Trans Cooler Line Asm, E H Trans Cooler 8.0000 sec 8.0000 sec - $0.19 1

Cooling System Motor Cooling Line Asm, E Motor 

Cooling

$54.35 Tool H Trans Cooler First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Line Asm, E Motor 

Cooling

$35.94 P.-P. Part H Trans Cooler H Trans Cooler Line, E Motor H Trans Cooler 4.0000 sec 4.0000 sec - $0.06 1

Line Asm, E Motor Cooling Line, E Motor 

Cooling Cooling

$35.94 Tool H Trans Cooler Extruder 32mm Base 0.0000 sec 0.0000 sec $0.00 $0.00 1

Line, E Motor 

Cooling

$35.94 Part H Trans Cooler H Trans Cooler Line, E Motor H Trans Cooler 0.0000 sec 12.2948 sec $0.59 $0.12 1

Line, E Motor Cooling, Material Line, E Motor 

Cooling Cooling, Material

- - - Box Size 410mmL x 165mmW x - - - - - -

93mmH

$54.35 Part H Trans Cooler H Hose Clamp, Medium (24mm) H Hose Clamp, 7.0000 sec 7.0000 sec $0.22 $0.11 1

Line Asm, E Motor Medium (24mm)

Cooling

$54.35 Part H Trans Cooler H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec 7.0000 sec $0.23 $0.11 1

Line Asm, E Motor Medium (27mm)

Cooling

$54.35 Tool H Trans Cooler Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.05 1

Line Asm, E Motor 

Cooling

$54.35 Fastening H Trans Cooler Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.03 2

Line Asm, E Motor 

Cooling

$54.35 Operation H Trans Cooler CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Line Asm, E Motor 

Cooling

$54.35 Part H Trans Cooler H Strap On Christmas Tree Clip H Strap On 10.0000 sec 10.0000 sec $0.04 $0.15 1

Line Asm, E Motor (#30) Christmas Tree 

Cooling Clip (#30)

$54.35 Fastening H Trans Cooler Zip Tie 3.0000 sec 3.0000 sec $0.00 $0.05 1

Line Asm, E Motor 

Cooling

Design Profit ®
Page 56 of

#

Copyright 2010 © Design Profit, Inc.
H Trans & DC-DC Cooling System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$54.35 Tool H Trans Cooler Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.05 1

Line Asm, E Motor 

Cooling

$54.35 Fastening H Trans Cooler Trim to Length 1.0000 sec 1.0000 sec $0.00 $0.02 1

Line Asm, E Motor 

Cooling

- - - Mate Cooler Junction (Photo N/A) - - - - - -

$83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.05 1

Cooling System

$83.31 Multitouch H Trans & DC-DC Regrab Cooler to Trans Hose Regrab Cooler to 8.0000 sec 8.0000 sec $0.00 $0.19 1

Cooling System Trans Hose

$83.31 Fastening H Trans & DC-DC Press in Xmass Clip 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

- - - Mate Cooler Hose to Trans - - - - - -

$83.31 Multitouch H Trans & DC-DC Regrab Cooler to Trans Hose Regrab Cooler to 8.0000 sec 8.0000 sec $0.00 $0.19 1

Cooling System Trans Hose

$83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.07 1

Cooling System

$83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec 2.0000 sec $0.00 $0.05 1

Cooling System

Report Totals Count: ##

681

Design Profit ®

Page 57 of #
Copyright 2010 © Design Profit, Inc.
Piece Co

(Total)

$0.00

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.40

-

-

-

Piece Co

(Total)

-

$0.00

$0.18

-

-

-

$0.00

-

$0.00

$0.02

$0.00

$0.00

$0.00

-

-

$0.00

-

$0.00

-

Piece Co

(Total)

$0.00

$0.03

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.10

$0.00

-

$0.00

-

$0.00

$0.15

-

Piece Co

(Total)

$0.18

$0.22

$0.21

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

-

$0.00

$0.00

-

$0.00

$0.05

-

-

-

$0.00

-

$0.00

Piece Co

(Total)

$0.08

-

-

-

$0.00

$0.00

$0.00

-

$0.00

-

$0.00

-

-

$0.00

-

$0.00

$0.14

-

Piece Co

(Total)

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.01

$0.00

$0.00

-

$0.00

-

$0.00

Piece Co

(Total)

$0.37

-

$0.46

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

$0.00

$0.55

-

Piece Co

(Total)

$1.19

$0.46

$0.00

$0.00

$0.00

$0.04

$0.00

$0.00

$0.00

-

$0.00

$0.05

-

-

-

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.12

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

-

$0.00

-

$0.00

Piece Co

(Total)

-

$0.00

-

$0.00

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

Piece Co

(Total)

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

Piece Co

(Total)

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

Piece Co

(Total)

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

Piece Co

(Total)

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

Piece Co

(Total)

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

Piece Co

(Total)

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

Piece Co

(Total)

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

Piece Co

(Total)

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

Piece Co

(Total)

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

Piece Co

(Total)

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

-

-

-

-

Piece Co

(Total)

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

-

$0.00

Piece Co

(Total)

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

Piece Co

(Total)

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

Piece Co

(Total)

-

$0.00

$0.08

-

$0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

-

$0.00

-

$0.00

$0.16

-

-

-

-

-

-

-

-

-

$0.00

$0.05

-

-

-

$0.00

-

Piece Co

(Total)

-

-

-

-

$0.00

$0.16

-

-

-

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

-

$0.08

-

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

$0.00

-

$0.00

-

$0.00

$0.13

$0.00

$0.00

$0.00

Piece Co

(Total)

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

$0.00

Piece Co

(Total)

-

$0.00

$0.13

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

-

Piece Co

(Total)

$0.00

$0.16

-

-

-

-

-

-

-

-

-

$0.00

$0.05

-

-

-

$0.00

-

-

-

-

-

$0.00

Piece Co

(Total)

$0.16

-

-

-

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

$0.00

-

$0.00

-

$0.00

$0.30

$0.00

$0.00

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

-

Piece Co

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Piece Co

(Total)

-

-

-

$0.00

-

$0.00

-

$0.00

$0.13

$0.00

$0.00

$0.00

-

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

$0.00

-

Piece Co

(Total)

$0.00

$0.13

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.10

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-
Piece Co

(Total)

$0.00

-

$0.00

-

$0.00

$0.13

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.57

-

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.06

$0.00

Piece Co

(Total)

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

$0.01

-

$0.00

$0.07

Piece Co

(Total)

$0.00

$0.00

$0.00

-

$0.00

-

$0.00

$0.25

-

$0.00

$0.00

$0.00

$0.23

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.06

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

-

-

$0.00

-

$0.00

$0.59

-

$0.22

$0.23

$0.00

$0.00

$0.00

$0.04

$0.00

Piece Co

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$23.64

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

09 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 02 Tensioners #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ 4.75 $ 2.64 $ 3.16 $ 10.55

4 03 Guides $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 05 Belts $ 4.89 $ 1.09 $ 4.89 $ 10.86 $ 0.05 $ 0.71 $ 0.65 $ 0.27 $ 1.68 $ 0.02 $ 12.56 $ - $ - $ - $ 2.85 $ 0.63 $ 2.85 $ 6.33

BASE TECHNOLOG

System 

ED&T/R&D

(x1000)

Sub-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:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

6 65 Adaptors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 75 Brackets #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

9 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

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

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

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

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

0 0 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

BASE TECHNOLOG

System 

ED&T/R&D

(x1000)

Sub-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:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

SUBSYSTEM ROLL-UP #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

09 Accessory Drive Subsystem

1 00

2 01

3 02

4 03

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

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

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

$ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ - $ - $ - #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ -

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

$ 0.03 $ 0.41 $ 0.38 $ 0.16 $ 0.98 $ 0.02 $ 7.33 $ - $ - $ - $ 2.04 $ 0.45 $ 2.04 $ 4.53 $ 0.02 $ 0.29 $ 0.27 $ 0.11 $ 0.70 $ - $ 5.23 $ - $ -

BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb 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 65

7 70

8 75

9 80

10 85

11 90

12 95

13 99

0 0

0 0

0 0

0 0

0 0

0 0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

0 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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb 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)

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

09 Accessory Drive Subsystem

1 00

2 01

3 02

4 03

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 65

7 70

8 75

9 80

10 85

11 90

12 95

13 99

0 0

0 0

0 0

0 0

0 0

0 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

0 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

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 4 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

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

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

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A Assembly of Accessory Drive Subsystem 01 09 00 - N0402- 01 1 Full 1

Only includes tensioner, tensioner 

spring assembly, and 

alternator/tensioner mounting 

bracket.

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

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 02 Tensioners #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A V Tensioner, Belt 01 09 02 - N0402- 01 1 Full 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

B V Belt Tensioner Spring Assembly 01 09 02 - N0402- 02 1 Full 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

4 03 Guides $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 05 Belts $ 4.89 $ 1.09 $ 4.89 $ 10.86 $ 0.05 $ 0.71 $ 0.65 $ 0.27 $ 1.68 $ 0.02 $ 12.56 $ -

A Belt - Accessory Drive 01 09 05 - N0402- 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

$ 4.89 $ 1.09 $ 4.89 $ 10.86 $ 0.05 $ 0.71 $ 0.65 $ 0.27 $ 1.68 $ 0.02 $ 12.56 $ -

6 65 Adaptors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 75 Brackets #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - N0402- 01 1 Full 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

9 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1

PIA to Assembly of Accessory A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

PIA to Assembly of Accessory 

Drive $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

Material Labor Burden End Item 

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

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - N0402- 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - N0402- 03 2 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - N0402- 04 1 Full 1

PIA to Assembly of Accessory 

Drive

E V Bolt, Belt Damper, Short 01 09 80 - N0402- 05 1 Full 1

PIA to Assembly of Accessory 

Drive

F V Bolt, Belt Damper Long 01 09 80 - N0402- 06 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

11 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

12 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

13 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

0

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem 

A Assembly of Accessory Drive Subsystem 01 09 00 - N0402- 01 1 Full 1

Only includes tensioner, tensioner 

spring assembly, and 

alternator/tensioner mounting 

bracket.

2 01 Pulleys

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

2 01 Pulleys

3 02 Tensioners

A V Tensioner, Belt 01 09 02 - N0402- 01 1 Full 1

B V Belt Tensioner Spring Assembly 01 09 02 - N0402- 02 1 Full 1

4 03 Guides

5 05 Belts

A Belt - Accessory Drive 01 09 05 - N0402- 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

6 65 Adaptors

7 70 Pipes, Hoses, Ducting

8 75 Brackets

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - N0402- 01 1 Full 1

9 80 Boltings

A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1

PIA to Assembly of Accessory 

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1 $ - $ -

PIA to Assembly of Accessory 

Drive $ - $ -

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

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - N0402- 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - N0402- 03 2 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - N0402- 04 1 Full 1

PIA to Assembly of Accessory 

Drive

E V Bolt, Belt Damper, Short 01 09 80 - N0402- 05 1 Full 1

PIA to Assembly of Accessory 

Drive

F V Bolt, Belt Damper Long 01 09 80 - N0402- 06 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

11 90 Bearings Elements Misc

12 95 Tools

13 99 Miscellaneous

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

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

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

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - #REF! $ -

A Assembly of Accessory Drive Subsystem 01 09 00 - B0402 - 01 1 Full 1

Used Vue hybrid cost sheet and 

ammended via service drawings #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - #REF! $ -

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 02 Tensioners $ 4.75 $ 2.64 $ 3.16 $ 10.55 $ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ -

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

3 02 Tensioners $ 4.75 $ 2.64 $ 3.16 $ 10.55 $ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ -

A Tensioner - 2.2 Liter Saturn Vue 01 09 02 - B0402 - 01 1 Full 0.18

Scaled service price based on ratio 

developed for Vue Hybrid developed 

cost versus service cost (5.6 Factor). 

Kept same cost element binning 

ratios.

$ 4.75 $ 2.64 $ 3.16 $ 10.55 $ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ -

4 03 Guides $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 05 Belts $ 2.85 $ 0.63 $ 2.85 $ 6.33 $ 0.03 $ 0.41 $ 0.38 $ 0.16 $ 0.98 $ 0.02 $ 7.33 $ -

A Belt - Accessory Drive 2.2 L Saturn Vue 01 09 05 - B0402 - 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

$ 2.85 $ 0.63 $ 2.85 $ 6.33 $ 0.03 $ 0.41 $ 0.38 $ 0.16 $ 0.98 $ 0.02 $ 7.33 $ -

6 65 Adaptors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 75 Brackets #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - B0402 - 01 1 Full 0.75

Scaled Vue Hybrid 

developed cost to account 

for less mounting content.

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

9 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - B0402 - 01 1 Full 1

PIA to Assembly of Accessory 

Drive $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

Material Labor Burden End Item 

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - B0402 - 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - B0402 - 03 1 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - B0402 - 04 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

N

Complete Subsystem Quote 

(Yes/No)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

0

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem 

A Assembly of Accessory Drive Subsystem 01 09 00 - B0402 - 01 1 Full 1

Used Vue hybrid cost sheet and 

ammended via service drawings

2 01 Pulleys

3 02 Tensioners

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

3 02 Tensioners

A Tensioner - 2.2 Liter Saturn Vue 01 09 02 - B0402 - 01 1 Full 0.18

Scaled service price based on ratio 

developed for Vue Hybrid developed 

cost versus service cost (5.6 Factor). 

Kept same cost element binning 

ratios.

4 03 Guides

5 05 Belts

A Belt - Accessory Drive 2.2 L Saturn Vue 01 09 05 - B0402 - 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

6 65 Adaptors

7 70 Pipes, Hoses, Ducting

8 75 Brackets

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - B0402 - 01 1 Full 0.75

Scaled Vue Hybrid 

developed cost to account 

for less mounting content.

9 80 Boltings

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - B0402 - 01 1 Full 1

PIA to Assembly of Accessory 

Drive $ - $ -

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

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - B0402 - 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - B0402 - 03 1 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - B0402 - 04 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements

11 90 Bearings Elements Misc

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

12 95 Tools

13 99 Miscellaneous

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

N

Complete Subsystem Quote 

(Yes/No)

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly. 9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $0.00

T1 or OEM Total Manufacturing Cost: $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Supplier for Subassembly.

3

1

Notes: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 #N/A #N/A #N/A #N/A #N/A #N/A $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: #N/A

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

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

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

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

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

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

$0.00

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411