### Page:1 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0.541818182

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

# 021100 Electric Motor & Controls Subsy **stem** 1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 2 **01 Traction and Generator Motors**  **197.55 $**  **115.46**

**$ 193.46** 

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$ 0.28** 

**$ 606.52** 

**$ Interpolate/Extrapolate 30kW & 60kW**  **Scaling Factor $2.74 kW** 

### 3 **02 Power Electronic Components and Assemblies**  **107.30 $**  **17.57**

**$ 32.74** 

**$ 157.61** 

**$ 1.49** 

**$ 15.19** 

**$ 13.68** 

**$ 5.84** 

**$ 36.20** 

**$ 0.45** 

**$ 194.26** 

**$ Surrogate IGBT Scaling Data**  **Reference Scale Supp WS** 

### 4 **03 Control Modules**  **400.05 $**  **17.07**

**$ 27.49** 

**$ 444.61** 

**$ 3.10** 

**$ 31.04** 

**$ 35.48** 

**$ 17.74** 

**$ 87.37** 

**$ 1.16** 

**$ 533.13** 

**$ Surrogate IGBT Scaling on High Power** 

**Component Portion** 

### 5 **04 Traction and Generator Motor Sensors**  **26.67 $**  **17.96**

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ Negligible Change** 

**Scaling Parameter(s) Description Notes**  

# 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)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Sub-Subsystem Description **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

5 **04 Traction and Generator Motor Sensors**  **26.67 $**  **17.96**

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ Negligible Change**  

### 6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  **23.39 $**  **31.05**

**$ 18.39** 

**$ 72.83** 

**$ 0.36** 

**$ 4.72** 

**$ 4.33** 

**$ 1.77** 

**$ 11.19** 

**$ 0.20** 

**$ 84.22** 

**$ Negligible Change**  

### 7 **10 Plugs**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 8 **15 Switches**  **0.67 $**  **1.06**

**$ 0.80** 

**$ 2.53** 

**$ 0.01** 

**$ 0.16** 

**$ 0.15** 

**$ 0.06** 

**$ 0.39** 

**$ 0.03** 

**$ 2.95** 

**$ Negligible Change**  

### 9 **72 Electrical Housings/Support Structure**  **35.11 $**  **7.36**

**$ 43.28** 

**$ 85.76** 

**$ 1.12** 

**$ 5.28** 

**$ 4.88** 

**$ 2.02** 

**$ 13.30** 

**$ 0.70** 

**$ 99.75** 

**$ Engine Torque**  

### 10 **75 Brackets**  **1.94 $**  **1.14**

**$ 0.53** 

**$ 3.61** 

**$ 0.01** 

**$ 0.19** 

**$ 0.12** 

**$ 0.03** 

**$ 0.35** 

**$ 0.10** 

**$ 4.06** 

**$ Negligible Change**  

### 11 **80 Boltings**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 12 **85 Sealing Elements**  **1.26 $**  **0.31**

**$ 0.52** 

**$ 2.10** 

**$ 0.01** 

**$ 0.14** 

**$ 0.13** 

**$ 0.02** 

**$ 0.29** 

**$ 0.02** 

**$ 2.41** 

**$ Engine Torque**  

### 13 **90 Bearing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 14 **91 Shims**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 15 **99 Miscellaneous**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### Material Deltas Base Based On Polar Moment of Inertia Calc's 35% Torque Reducion Results in 25% M aterial Reduction 22% Troque Reduction Results in 15% Material Reduction 46% Increase in Torque Results in a 28% Increase in Material Burden Based on Stamping Circ. 35% Torque Reducion Results in 13.4% Burden Reduction 22% Troque Reduction Results in 8% Burden Reduction 46% Increase in Torque Results in a 13.4% Increase in Material



### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:2 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0.541818182

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **Scaling Parameter(s) Description Notes**  

# 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)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Sub-Subsystem Description **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 793.95 **$ 208.98** 

**$ 337.24** 

**$ 1,340.17** 

**$ 10.01** 

**$ 96.40** 

**$ 103.22** 

**$ 49.50** 

**$ 259.12** 

**$ 3.25** 

**$ 1,602.54** 

**$ -** 

**$** 

### 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 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0.541818182

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **Scaling Parameter(s) Description Notes**  

# 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)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Sub-Subsystem Description **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

# 05 **Cy linder Blocks**  A1 **01** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!** 

### 2 #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!** E1 **65** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** F1 **66 Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

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

# BASE **TECHNO LOGY**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem



### F1 **66** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$**

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

### Page:4 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0.541818182

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **Scaling Parameter(s) Description Notes**  

# 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)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Sub-Subsystem Description **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

G1 **67** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** $ $ $ **$** $ $ $ $ **$** $ **$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### 2 - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$ SU**  **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

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

# 05 **Cy linder Blocks**  A1 **01** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### B1 **02** 197.55 $ 115.46

$ 193.46

$ **506.47**

**$** 3.55

$ 35.45

$ 40.52

$ 20.26

$ **99.77**

**$** 0.28

$ **606.52**

**$** 

### C1 **03** 107.30 $ 17.57

$ 32.74

$ **157.61**

**$** 1.49

$ 15.19

$ 13.68

$ 5.84

$ **36.20**

**$** 0.45

$ **194.26**

**$** 

### D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!** 

### E1 **65 64.66**  **$ 10.26**  **$ 75.24**  **$** 

# TECHNO **LOGY PACKAG**  **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**ItemSubsystemSub-Subsystem Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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



### E1 **65** 26.67 $ 17.96

$ 20.02

$ **64.66**

**$** 0.36

$ 4.22

$ 3.93

$ 1.75

$ **10.26**

**$** 0.33

$ **75.24**

**$**



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

### Page:5 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0.541818182

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **Scaling Parameter(s) Description Notes**  

# 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)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Sub-Subsystem Description **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

F1 **66** 23.39 $ 31.05

$ 18.39

$ **72.83**

**$** 0.36

$ 4.72

$ 4.33

$ 1.77

$ **11.19**

**$** 0.20

$ **84.22**

**$** 

### G1 **67** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### H1 **70** 0.67 $ 1.06

$ 0.80

$ **2.53**

**$** 0.01

$ 0.16

$ 0.15

$ 0.06

$ **0.39**

**$** 0.03

$ **2.95**

**$** 

### I1 **75** 35.11 $ 7.36

$ 43.28

$ **85.76**

**$** 1.12

$ 5.28

$ 4.88

$ 2.02

$ **13.30**

**$** 0.70

$ **99.75**

**$** 

### J1 **80** 1.94 $ 1.14

$ 0.53

$ **3.61**

**$** 0.01

$ 0.19

$ 0.12

$ 0.03

$ **0.35**

**$** 0.10

$ **4.06**

**$** 

### K1 **85** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### L1 **90** 1.26 $ 0.31

$ 0.52

$ **2.10**

**$** 0.01

$ 0.14

$ 0.13

$ 0.02

$ **0.29**

**$** 0.02

$ **2.41**

**$** $ $ **$ $**  $ **$**



### - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### N1 **00** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

**$** -

$ **-**

**$** 

### SU **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

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

### Page:6 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# 021100 Electric Motor & Controls Subsy **stem** 1 **00** 2 **01** 3 **02** 4 **03** 5 **04** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem **Scaling Factor**

**Relative to Baseline**  **(Ford Fusion) Value**  **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value Scaling Factor**  **Relative to Baseline**  **(Ford Fusion) Value**  Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 2.743**  **493.71**

**$ 2.743**  **516.04 $**  **2.743 652.32**  **$ -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 197.55** 

**$ 0.54**  **139.33**

**$ 0.63** 

**$ 151.99** 

**$ 1.19**  **222.78 $**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 107.30** 

**$ 0.54**  **447.99**

**$ 0.63** 

**$ 467.62** 

**$ 1.19**  **577.33 $**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 400.05** 

**$ 75.24**  **$ 75.24**  **$ 75.24**  **$ -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 26.67** 

**$ Sub-Compact Vehicle Segment**  **(e.g Ford Fiesta) Small/Compact Vehicle Segment**  **(e.g Ford Fusion)** 

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

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### 5 **04** 6 **05** 7 **10** 8 **15** 9 **72** 10 **75** 11 **80** 12 **85** 13 **90** 14 **91** 15 **99** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a 75.24**  **$ 75.24**  **$ 75.24**  **$ -**  **$ -** 

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

### Page:7 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### 0 **n/a Scaling Factor** 

**Relative to Baseline**  **(Ford Fusion) Value**  **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value Scaling Factor**  **Relative to Baseline**  **(Ford Fusion) Value**  Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material **Sub-Compact Vehicle Segment (e.g Ford Fiesta)**  **Small/Compact Vehicle Segment (e.g Ford Fusion)**  

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

**(X1000) Large Size Vehicle Segment**  **(e.g Ford Flex)**

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### ######

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

### Page:8 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value Scaling Factor**  **Relative to Baseline**  **(Ford Fusion) Value**  **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value** Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material **Sub-Compact Vehicle Segment (e.g Ford Fiesta)**  **Small/Compact Vehicle Segment (e.g Ford Fusion)**  

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

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

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

**(x1000) Investment** 

**(X1000) Large Size Vehicle Segment**  **(e.g Ford Flex)**



# 05 **Cy linder Blocks**  A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 

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# BASE TECHNOLOGY PACKAGE COST INFORMATION Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Investment**  **(X1000)**



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

### Page:9 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### G1 **67** 2 H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99 Scaling Factor** 

**Relative to Baseline**  **(Ford Fusion) Value**  **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value Scaling Factor**  **Relative to Baseline**  **(Ford Fusion) Value**  Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material **Sub-Compact Vehicle Segment (e.g Ford Fiesta)**  **Small/Compact Vehicle Segment (e.g Ford Fusion)**  

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

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**(x1000) Investment** 

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### M1 **99** 2 N1 **00** 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks**  A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem - $ -

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# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 



### E1 **65** - $ -

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

### Page:10 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### F1 **66** G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90 Scaling Factor** 

**Relative to Baseline**  **(Ford Fusion) Value**  **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value Scaling Factor**  **Relative to Baseline**  **(Ford Fusion) Value**  Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material **Sub-Compact Vehicle Segment (e.g Ford Fiesta)**  **Small/Compact Vehicle Segment (e.g Ford Fusion)**  

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

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**(x1000) Investment** 

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

### Page:11 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# 021100 Electric Motor & Controls Subsy **stem** 1 **00** 2 **01** 3 **02** 4 **03** 5 **04** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem Labor Burden End Item Scrap SG&A Profit ED&T-R&D

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)**  **Tooling (x1000)** 



### 5 **04** 6 **05** 7 **10** 8 **15** 9 **72** 10 **75** 11 **80** 12 **85** 13 **90** 14 **91** 15 **99** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a 17.96** 

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**$ 75.24** 

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**- $**  **-**

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### 0 **n/a $**  **$ $**  **$ $**  **$ $**  **$ $**  **$**



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

### Page:12 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### 0 **n/a** Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)**  **Tooling (x1000)** 

**- $**  **-**

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### 208.98 **$ 337.24** 

**$ 1,340.17** 

**$ 10.01** 

**$ 96.40** 

**$ 103.22** 

**$ 49.50** 

**$ 259.12** 

**$ 3.25** 

**$ 1,602.54** 

**$ #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:13 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)**  **Tooling (x1000)** 



# 05 **Cy linder Blocks**  A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 

# BASE **TECHNO LOGY** ItemSubsystemSub-Subsystem



### F1 **66** 2

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

### Page:14 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### G1 **67** 2 H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99** Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)**  **Tooling (x1000)** 



### M1 **99** 2 N1 **00** 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks**  A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem



### E1 **65**

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

### Page:15 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### F1 **66** G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90** Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)**  **Tooling (x1000)** 



### L1 **90** M1 **99** N1 **00**

**SU BS**  **YS**

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

# Voltage (V) Current (A) # of IGBTs IPM or IGBT 50 600 150 6 IPM 96.89 1200 35 6 IPM 60.7 1200 50 6 IPM 64.38 600 30 6 IPM 39.81 1200 140 6 IPM 142.98 IPM in Fusion 300 1 IPM ? IPM Estimated equivilent 6 pak module 300 6 IPM ? Sem ikron IPM Costing

1200 Volt Current/Cost Characteristics

60 80 100 120 140 160**C o** **s t** **p e** **r U** **n i** **t** 

# Cost vs Current Rating

140 A 50A 35 A 

## 30

40 50 60**C o** **s t** **p e** **r U** **n i** **t**



# Projected Cost/Unit @ higher currents 0 20 40 60 80

0 50 100 150 200**C o** **s t** **p e** **r U** **n i** **t**



## Quantity **of Purchase** 50A 35 A



## 0

10 20 30

0 500000**C o** **s t** **p e** **r U** **n i** **t**



## 300

350 400

# Current (A) Cost @ 50 ($) Cost @ 100 ($) Cost @ 150 ($) Formula -> 5.5298x^(0.653) 4.8032x^(0.6524) 4.4282x^(0.6527) 150 145.78 126.24 116.56 200 175.91 152.31 140.64 250 203.50 176.18 162.69 300 229.23 198.43 183.25 350 253.50 219.42 202.65 400 276.60 239.39 221.10 0 50 100 150 200 250 300

0**C o** **s t** **p e** **r U** **n i** **t (** **$ )** 



# 60.00 70.00 80.00 90.00 100.00**C o** **s t** **p e** **r U** **n i** **t (** **$ )**  

# Cost Projection per Unit for Hy **brid A pplication**  **IPMs (6 IGBT s)** 

0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00

0 500000 1000000 1500000 2000000**C o** **s t** **p e** **r U** **n i** **t (** **$ )** 



# Quantity of Purchase

# 100 150 Part # Link

83.93 77.46 Skiip 39AC066V4 http://www.sindopower.com /en/Products-And52.57 48.51 Skiip 24NAB12T4V1 http://www.sindopower.com /en/Products-And55.87 51.55 Skiip 25AC12T4V1 http://www.sindopower.com /en/Products-And34.41 31.62 Skiip 25NEB066V1 http://www.sindopower.com /en/Products-And123.81 114.28 SkiiP 39AC126V2 http://www.sindopower.com /en/Products-And- ? 15.00 ? - - ? 90-100 Cost Per:

1200 Volt Current/Cost Characteristics **Cost vs Current Rating cost curve**

Power (140 A)



## 500000 1000000 1500000 2000000 2500000 **Quantity of Purchase**  Power (140 A) Power (50A) Power (35 A)



## y = 5.5298x 0.653 

# Current vs. Cost

## y = 4.4282x 0.6527 

## y = 4.8032x 0.6524



## 100 200 300 400 500 600

**Current (A**

**)** Power (150 Units) Power (50 Units) Power (100 Units)



# Cost Projection per Unit for Hy **brid A pplication**  **IPMs (6 IGBT s)** 

2000000 2500000 Power (400 A) Power (350 A) Power (300 A)

# % Voltage % Cost 600 77.46 0.85714286 700 83.60 0.92659197 0.75 800 89.73 0.86322437 0.66666667 900 95.87 0.80796912 0.6 1000 102.01 0.75936213 0.54545455 1100 108.14 0.71627161 0.5 1200 114.28 0.67780889

0.71722222 0.78242424 1.14681606

### Page:1 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

# 021100 Electric Motor & Controls Subsy **stem** 1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 2 **01 Traction and Generator Motors**  **197.55 $**  **115.46**

**$ 193.46** 

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$ 0.28** 

**$ 606.52** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 3 **02 Power Electronic Components and Assemblies**  **107.30 $**  **17.57**

**$ 32.74** 

**$ 157.61** 

**$ 1.49** 

**$ 15.19** 

**$ 13.68** 

**$ 5.84** 

**$ 36.20** 

**$ 0.45** 

**$ 194.26** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 4 **03 Control Modules**  **400.05 $**  **17.07**

**$ 27.49** 

**$ 444.61** 

**$ 3.10** 

**$ 31.04** 

**$ 35.48** 

**$ 17.74** 

**$ 87.37** 

**$ 1.16** 

**$ 533.13** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **04 Traction and Generator Motor Sensors**  **26.67 $**  **17.96**

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ System**  **ED&T/R&D (x1000)**  **Investment (X1000)**  **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  **23.39 $**  **31.05**

**$ 18.39** 

**$ 72.83** 

**$ 0.36** 

**$ 4.72** 

**$ 4.33** 

**$ 1.77** 

**$ 11.19** 

**$ 0.20** 

**$ 84.22** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 7 **10 Plugs**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 8 **15 Switches**  **0.67 $**  **1.06**

**$ 0.80** 

**$ 2.53** 

**$ 0.01** 

**$ 0.16** 

**$ 0.15** 

**$ 0.06** 

**$ 0.39** 

**$ 0.03** 

**$ 2.95** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 9 **72 Electrical Housings/Support Structure**  **35.11 $**  **7.36**

**$ 43.28** 

**$ 85.76** 

**$ 1.12** 

**$ 5.28** 

**$ 4.88** 

**$ 2.02** 

**$ 13.30** 

**$ 0.70** 

**$ 99.75** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 10 **75 Brackets**  **1.94 $**  **1.14**

**$ 0.53** 

**$ 3.61** 

**$ 0.01** 

**$ 0.19** 

**$ 0.12** 

**$ 0.03** 

**$ 0.35** 

**$ 0.10** 

**$ 4.06** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 11 **80 Boltings**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 12 **85 Sealing Elements**  **1.26 $**  **0.31**

**$ 0.52** 

**$ 2.10** 

**$ 0.01** 

**$ 0.14** 

**$ 0.13** 

**$ 0.02** 

**$ 0.29** 

**$ 0.02** 

**$ 2.41** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 13 **90 Bearing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 14 **91 Shims**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 15 **99 Miscellaneous**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$** 

### 0 **n/a n/a**  **- $**  **-**

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### 0 **n/a n/a**  **- $**  **-**

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### 0 **n/a n/a**  **- $**  **-**

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### 0 **n/a n/a**  **- $**  **-**

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### 0 **n/a n/a**  **- $**  **-**

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

### Page:2 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden **System ED&T/R&D**  **(x1000) Investment**  **(X1000) Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

**793.95 $**  **208.98**

**$ 337.24** 

**$ 1,340.17** 

**$ 10.01** 

**$ 96.40** 

**$ 103.22** 

**$ 49.50** 

**$ 259.12** 

**$ 3.25** 

**$ 1,602.54** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### -

**$ -** 

**$ -** 

**$ -** 

**$ 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 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden **System ED&T/R&D**  **(x1000) Investment**  **(X1000) Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

# 05 **Cy linder Blocks**  A1 **01** - $ -

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

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$ **-**

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### 2 - $ -

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$ **-**

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### -

$ -

$ -

$ **-**

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

$ -

$ **-**

**$** -

$ -

$ -

$ -

$ **-**

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$ **-**

**$** -

$ -

$ -

$ -

$ -

$ -

$ **-**

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$ -

$ #REF! #REF! #REF! **#REF!** 

### 2 #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

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### #REF! #REF! #REF! **#REF!** E1 **65** - $ -

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# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem **Total Packaging**  **Cost (Component**  **/ Assembly) Net** 

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

# BASE **TECHNO LOGY**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Total Markup**  **Cost (Component/**  **Assembly) Investment**  **(X1000)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATION Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000)**



### G1 **67** - $ -

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

### Page:4 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden **System ED&T/R&D**  **(x1000) Investment**  **(X1000) Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

H1 **70** - $ -

$ -

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

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**$ SU**  **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

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### #REF! #REF! #REF! **#REF!**

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

# 05 **Cy linder Blocks**  A1 **01** - $ -

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### B1 **02** 197.55 $ 115.46

$ 193.46

$ **506.47**

**$** 3.55

$ 35.45

$ 40.52

$ 20.26

$ **99.77**

**$** 0.28

$ **606.52**

**$** -

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### C1 **03** 107.30 $ 17.57

$ 32.74

$ **157.61**

**$** 1.49

$ 15.19

$ 13.68

$ 5.84

$ **36.20**

**$** 0.45

$ **194.26**

**$** -

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

$ -

$ #REF! #REF! #REF! **#REF!** 

### E1 **65** 26.67 $ 17.96

$ 20.02

$ **64.66**

**$** 0.36

$ 4.22

$ 3.93

$ 1.75

$ **10.26**

**$** 0.33

$ **75.24**

**$** -

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### F1 **66 72.83**  **$ 11.19**  **$ 84.22**  **$ -**  **$**ItemSubsystemSub-Subsystem Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

# TECHNO **LOGY PACKAG**  **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Investment**  **(X1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000)**



### F1 **66** 23.39 $ 31.05

$ 18.39

$ **72.83**

**$** 0.36

$ 4.72

$ 4.33

$ 1.77

$ **11.19**

**$** 0.20

$ **84.22**

**$** -

$ -

$ -

$ -

$ -

$ -

$ **-**

**$**



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

### Page:5 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden **System ED&T/R&D**  **(x1000) Investment**  **(X1000) Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

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

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

G1 **67** - $ -

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$ -

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### H1 **70** 0.67 $ 1.06

$ 0.80

$ **2.53**

**$** 0.01

$ 0.16

$ 0.15

$ 0.06

$ **0.39**

**$** 0.03

$ **2.95**

**$** -

$ -

$ -

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$ -

$ **-**

**$** 

### I1 **75** 35.11 $ 7.36

$ 43.28

$ **85.76**

**$** 1.12

$ 5.28

$ 4.88

$ 2.02

$ **13.30**

**$** 0.70

$ **99.75**

**$** -

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$ **-**

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### J1 **80** 1.94 $ 1.14

$ 0.53

$ **3.61**

**$** 0.01

$ 0.19

$ 0.12

$ 0.03

$ **0.35**

**$** 0.10

$ **4.06**

**$** -

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### L1 **90** 1.26 $ 0.31

$ 0.52

$ **2.10**

**$** 0.01

$ 0.14

$ 0.13

$ 0.02

$ **0.29**

**$** 0.02

$ **2.41**

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### SU **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

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

### Page:6 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# 021100 Electric Motor & Controls Subsy **stem** 1 **00** 2 **01** 3 **02** 4 **03** 5 **04**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

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

**- $**  **-**

**$ -** 

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**$ 197.55** 

**$ 115.46** 

**$ 193.46** 

**$ 506.47** 

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**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$ 0.28** 

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**$ 17.57** 

**$ 32.74** 

**$ 157.61** 

**$ 1.49** 

**$ 15.19** 

**$ 13.68** 

**$ 5.84** 

**$ 36.20** 

**$ 0.45** 

**$ 194.26** 

**$ -** 

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**$ 400.05** 

**$ 17.07** 

**$ 27.49** 

**$ 444.61** 

**$ 3.10** 

**$ 31.04** 

**$ 35.48** 

**$ 17.74** 

**$ 87.37** 

**$ 1.16** 

**$ 533.13** 

**$ -** 

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**$ 26.67** 

**$ 17.96** 

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ -** 

**$ -** 

**$** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

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

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

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

**(x1000) Investment** 

**(X1000) System**  **ED&T/R&D (x1000)** 



### 6 **05** 7 **10** 8 **15** 9 **72** 10 **75** 11 **80** 12 **85** 13 **90** 14 **91** 15 **99** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

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**$ -** 

**$ 23.39** 

**$ 31.05** 

**$ 18.39** 

**$ 72.83** 

**$ 0.36** 

**$ 4.72** 

**$ 4.33** 

**$ 1.77** 

**$ 11.19** 

**$ 0.20** 

**$ 84.22** 

**$ -** 

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**$ 0.67** 

**$ 1.06** 

**$ 0.80** 

**$ 2.53** 

**$ 0.01** 

**$ 0.16** 

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**$ 0.06** 

**$ 0.39** 

**$ 0.03** 

**$ 2.95** 

**$ -** 

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**$ 35.11** 

**$ 7.36** 

**$ 43.28** 

**$ 85.76** 

**$ 1.12** 

**$ 5.28** 

**$ 4.88** 

**$ 2.02** 

**$ 13.30** 

**$ 0.70** 

**$ 99.75** 

**$ -** 

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**$ 1.94** 

**$ 1.14** 

**$ 0.53** 

**$ 3.61** 

**$ 0.01** 

**$ 0.19** 

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**$ 0.35** 

**$ 0.10** 

**$ 4.06** 

**$ -** 

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**$ 1.26** 

**$ 0.31** 

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**$ 2.10** 

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**$ 0.29** 

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**$ 2.41** 

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

### Page:7 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

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

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

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

**(x1000) Investment** 

**(X1000) System**  **ED&T/R&D (x1000)** 



### - **$ -** 

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**$ 1,340.17** 

**$ 10.01** 

**$ 96.40** 

**$ 103.22** 

**$ 49.50** 

**$ 259.12** 

**$ 3.25** 

**$ 1,602.54** 

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

### Page:8 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

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

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

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

**(x1000) Investment** 

**(X1000) System**  **ED&T/R&D (x1000)** 



# 05 **Cy linder Blocks**  A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 2ItemSubsystemSub-Subsystem 

# BASE **TECHNO LOGY** 

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# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Tooling (x1000)**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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



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

### Page:9 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99** 2 N1 **00** End Item

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

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

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

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

**(x1000) Investment** 

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# 05 **Cy linder Blocks**  A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** F1 **66**ItemSubsystemSub-Subsystem 

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)** 



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

### Page:10 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90** M1 **99** End Item

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

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

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

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

**(x1000) Investment** 

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

### Page:11 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# 021100 Electric Motor & Controls Subsy **stem** 1 **00** 2 **01** 3 **02** 4 **03** 5 **04**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**- $** 

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

### Page:12 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Investment(X1 000)** 

**- $** 



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

### Page:13 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Investment(X1 000)** 



# 05 **Cy linder Blocks**  A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 2ItemSubsystemSub-Subsystem 

# BASE **TECHNO LOGY** 

G1 **67** 2

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

### Page:14 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99** 2 N1 **00 Investment(X1** 

**000)**



### 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks**  A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** F1 **66**ItemSubsystemSub-Subsystem 

# TECHNO **LOGY PACKAG** 

F1 **66**

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

### Page:15 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90** M1 **99 Investment(X1** 

**000)**



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

### Page:1 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

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Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:2 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:3 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:4 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:5 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:6 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:7 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:8 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:9 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:10 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

13 **90 Bearing Elements**  **- $**  **-**

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

### Page:11 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:12 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

- $ -

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**$** 16 **na na**  **- $**  **-**

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**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:13 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

### Page:14 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0 **n/a n/a**  

# 021100 Electric Motor & Controls Subsy **stem** 1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

### Page:15 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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### 3 **02 Power Electronic Components and Assemblies**  - $ **-**

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

### Page:16 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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### 4 **03 Control Modules**  - $ **-**

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

### Page:17 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

5 **04 Traction and Generator Motor Sensors**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

- $ **-**

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### 6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  - $ **-**

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

### Page:18 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

- $ **-**

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### 7 **10 Plugs**  - $ **-**

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

### Page:19 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

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

### Page:20 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

9 **72 Electrical Housings/Support Structure**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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### 10 **75 Brackets**  - $ **-**

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

### Page:21 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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### 11 **80 Boltings**  - $ **-**

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

### Page:22 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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### 12 **85 Sealing Elements**  **- $**  **-**

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

### Page:23 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

13 **90 Bearing Elements**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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### 14 **91 Shims**  - $ **-**

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

### Page:24 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

### Page:25 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

16 **na na**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

- $ **-**

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### 17 **na na**  18 **na na** 

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

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

### Page:26 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# 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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power - Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4 - 6 Passengers 

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

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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: **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: Part Number:**  **0211**-N0502-  

## We ekly Component Volume: Packaging Specification: ** Component Quote Level:** Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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** 

### 9,574 **10 North America**  **North America FOB Ship Point**  **47 450,000**  **1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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: **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: Part Number:**  **0211**-N0502-  

## We ekly Component Volume: Packaging Specification: ** Component Quote Level:** Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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: **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: Part Number:**  **0211**-N0502-  

## We ekly Component Volume: Packaging Specification: ** Component Quote Level:** Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### 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 Sub Assembly. "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: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:**  ----- ----- ----- ----- #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 all equal same value otherwise there is a computation**  **error.**



### 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:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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: **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: Part Number:**  **0211**-N0502-  

## We ekly Component Volume: Packaging Specification: ** Component Quote Level:** Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **) 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:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a k** **t T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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 Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a k** **t T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d** 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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**  **#DIV/0! #DIV/0!**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!** - - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a k** **t T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d** 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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**  **$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:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a k** **t T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d** 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#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:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!**  - **#DIV/0! #DIV/0!**  - **#DIV/0! #DIV/0!**  - **#DIV/0! #DIV/0!**  - **#DIV/0! #DIV/0!**  - **#DIV/0! #DIV/0!**  - **#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

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### 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:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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