### Page:1 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFT

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  

# 03 **Body Sy**  **stem D**

**11 Glass (Glazing), Frame, and Mechanism Subsystem** 

1 **01 Windshield and Front Quarter Window (Fixed)**  **3.33 1.19**  **17.30 21.82**  **0.05 1.10**  **0.73 0.18**  **2.06**

**- 23.88** 

**- -**  **- 4.02**  **1.43 14.83** 



### 2 **03 First Row Door Window Lift Assy**  **7.87 0.40**  **1.32 9.59**  **0.02 0.48**  **0.32 0.08**  **0.91**

**- 10.49** 

**- -**  **- 5.70**  **0.40 1.32** 



### 3 **04 Rear Quarter Window Assembly (Moveable)** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 4 **05 Back and Rear Quarter Windows (Fixed)**  **0.99 0.33**  **8.32 9.63**  **0.02 0.48**  **0.32 0.08**  **0.91**

**- 10.54** 

**- -**  **- 1.09**  **0.36 7.43**  Manufacturing 

# NEW TECHNOLOGY GENERAL PART INFORMATION

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to** 

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

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

### Sub-Subsystem DescriptionSystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Investment (X1000)**  

# Technology **Level:** Toyota Venza Mass

- Reduction and Cost Analysis **Vehicle Class:** Small & Mid Size Cross

- Over Passenger Vehicle **Study Case#:** 07

- 069

- 303LW

4 **05 Back and Rear Quarter Windows (Fixed)**  **0.99 0.33**  **8.32 9.63**  **0.02 0.48**  **0.32 0.08**  **0.91**

**- 10.54** 

**- -**  **- 1.09**  **0.36 7.43** 



### 5 **09 Power Window Electronics** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 6 **11 Second Row Door, Qtr & Rear Closure Window Lift Assy**  **7.87 0.40**  **1.32 9.59**  **0.02 0.48**  **0.32 0.08**  **0.91**

**- 10.49** 

**- -**  **- 5.70**  **0.40 1.32** 



### 7 **12 Back Window Assy**  **3.47 1.72**  **43.97 49.17**  **0.12 2.47**  **1.65 0.41**  **4.65**

**- 53.82** 

**- -**  **- 4.02**  **1.91 39.32** 



### 8 **13 Front Side Door Glass** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 9 **14 Rear Side Door Glass**  **2.39 1.66**  **42.47 46.52**  **0.12 2.34**  **1.56 0.39**  **4.40**

**- 50.93** 

**- -**  **- 2.91**  **1.85 37.97** 



### 10 **14 Handles, Locks, Latches and Mechanisms Subsystem** 

11

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 12 **15 Rear Hatch Lift Assembly Mechanism** 

13

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 14 **16 Wipers & Washers Subsystem** 

15 **99 Solvent Bottle**  **1.99 0.08**  **0.10 2.17**  **0.02 0.24**  **0.19 0.04**  **0.48**

**- 2.66** 

**- -**  **- 2.31**  **0.09 0.12** 



### 16

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 09000064810d3b0c.xls
EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFT

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

# NEW TECHNOLOGY GENERAL PART INFORMATION

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to** 

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

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

### Sub-Subsystem DescriptionSystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Investment (X1000)**  

# Technology **Level:** Toyota Venza Mass

- Reduction and Cost Analysis **Vehicle Class:** Small & Mid Size Cross

- Over Passenger Vehicle **Study Case#:** 07

- 069

- 303LW

**27.90 5.78**  **114.79 148.48**  **0.38 7.59**  **5.09 1.26**  **14.33**

**- 162.81** 

**- -**  **-** 

### 25.76 **6.44 102.31**  **SUBSYSTEM ROLL-UP**

09000064810d3b0c.xls
EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFT



# 03 **Body Sy**  **stem D**

**11 Glass (Glazing), Frame, and Mechanism Subsystem** 

1 **01**

2 **03**

3 **04**

4 **05**ItemSubsystemSystem

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD** 

**20.28 0.05**  **1.02 0.68**  **0.17 1.92** 

**- 22.20** 

**- -**  **- 0.69**  **0.24 (2.47)**  **(1.54) (0.00)**  **(0.08) (0.05)**  **(0.01) (0.15)** 

**- (1.68)** 

**-**

**7.42 0.02**  **0.37 0.25**  **0.06 0.70** 

**- 8.13** 

**- -**  **- (2.16)** 

**- -**  **(2.16) (0.01)**  **(0.11) (0.07)**  **(0.02) (0.20)** 

**- (2.37)** 

**-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**8.89 0.02**  **0.45 0.30**  **0.07 0.84** 

**- 9.73** 

**- -**  **- 0.10**  **0.04 (0.88)**  **(0.74) (0.00)**  **(0.04) (0.02)**  **(0.01) (0.07)** 

**- (0.81)** 

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

**(x1000) Investment** 

**(X1000) Total**  **Manufacturing**

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

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

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

**OEM** 

# 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

4 **05**

5 **09**

6 **11**

7 **12**

8 **13**

9 **14**

10 **14 Handles, Locks, Latches and Mechanisms Subsystem** 

11

12 **15 Rear Hatch Lift Assembly Mechanism** 

13

14 **16 Wipers & Washers Subsystem** 

15 **99**

16 **8.89 0.02**  **0.45 0.30**  **0.07 0.84** 

**- 9.73** 

**- -**  **- 0.10**  **0.04 (0.88)**  **(0.74) (0.00)**  **(0.04) (0.02)**  **(0.01) (0.07)** 

**- (0.81)** 

**-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**7.42 0.02**  **0.37 0.25**  **0.06 0.70** 

**- 8.13** 

**- -**  **- (2.16)** 

**- -**  **(2.16) (0.01)**  **(0.11) (0.07)**  **(0.02) (0.20)** 

**- (2.37)** 

**-**

**45.24 0.11**  **2.27 1.52**  **0.38 4.28** 

**- 49.53** 

**- -**  **- 0.54**  **0.19 (4.65)**  **(3.92) (0.01)**  **(0.20) (0.13)**  **(0.03) (0.37)** 

**- (4.29)** 

**-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**42.73 0.11**  **2.15 1.43**  **0.36 4.04** 

**- 46.78** 

**- -**  **- 0.52**  **0.18 (4.49)**  **(3.79) (0.01)**  **(0.19) (0.13)**  **(0.03) (0.36)** 

**- (4.15)** 

**-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**2.51 0.02**  **0.28 0.22**  **0.04 0.56** 

**- 3.07** 

**- -**  **- 0.32**  **0.01 0.01**  **0.34 0.00**  **0.04 0.03**  **0.01 0.08** 

**- 0.42** 

**-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 09000064810d3b0c.xls
EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFTItemSubsystemSystem

End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System**
**ED&T/R&D (x1000)**  **System**
**ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000) Total**  **Manufacturing**

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

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

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

**OEM** 

# 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

**134.50 0.35**  **6.91 4.64**  **1.15 13.05** 

**- 147.56** 

**- -**  **-** 

### (2.15) **0.66 (12.48)**  **(13.97) (0.03)**  **(0.68) (0.45)**  **(0.11) (1.28)** 

**- (15.25)** 

**-**



### 09000064810d3b0c.xls
EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFT



# 03 **Body Sy**  **stem D**

**11 Glass (Glazing), Frame, and Mechanism Subsystem** 

1 **01**

2 **03**

3 **04**

4 **05**ItemSubsystemSystem



### USD **USD**

**- -** 

**- -** 

**- -** 

**- -**  **Tooling (x1000)**  **Investment**

**(X1000)**



### 4 **05**

5 **09**

6 **11**

7 **12**

8 **13**

9 **14**

10 **14 Handles, Locks, Latches and Mechanisms Subsystem** 

11

12 **15 Rear Hatch Lift Assembly Mechanism** 

13

14 **16 Wipers & Washers Subsystem** 

15 **99**

16 **- -** 

**- -** 

**- -** 

**- -** 

**- -** 

**- -** 

**- -** 

**- -** 

**- -** 

**- -** 



### 09000064810d3b0c.xls
EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFTItemSubsystemSystem **Tooling (x1000)**  **Investment**

**(X1000)**

**- -** 



### 09000064810d3b0c.xls
EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

# Description **Base**

**Ma ss**  **New**

**Ma ss**  **Base Glass**

**Thickness (mm) New Glass** 

**Thickness (mm) Base**  **New Differential**  **Percent**

**Increase**

Front Quarter Fixed W indow 0.335 0.218 4.85 3.15 $2.56 $2.80 $0.24 9.5%

Rear Quarter Fixed W indow 0.64 0.525 3.85 3.15 $4.86 $5.27 $0.41 8.4%

Front Side W indow 4.393 2.855 4.85 3.15 $31.43 $34.58 $3.15 10.0%

Rear Side W indow 3.269 2.681 3.85 3.15 $23.39 $25.46 $2.07 8.9%

Backlight 6.769 5.551 3.85 3.15 $49.53 $53.82 $4.29 8.7%

Wi ndshield - Inner Lay er 6.55 5.830 2.1 1.6 $22.20 $23.88 $1.68 7.6% **Part Information FEV Cost (including mark-up)** 

# Base Cycle

**Time (s) New Cycle** 

**Time (s) Base Burden** 

**($/hr) New Burden** 

**($/hr) Base Cycle** 

**Time (s) New Cycle** 

**Time (s) Base Burden** 

**($/hr) New Burden** 

**($/hr)**

1.0 0.7 $ 2,512.41 $ 5,401.69 2.5 2.5 $ 1,796.89 $ 1,814.74

1.9 1.6 $ 2,512.41 $ 4,019.86 4.8 4.8 $ 1,796.89 $ 1,814.74

13.1 8.5 $ 2,512.41 $ 5,401.69 32.8 32.8 $ 1,796.89 $ 1,814.74

9.8 8.0 $ 2,512.41 $ 4,019.86 24.4 24.4 $ 1,796.89 $ 1,814.74

20.2 16.6 $ 2,512.41 $ 4,019.86 25.3 25.3 $ 3,593.77 $ 3,629.47

19.6 14.9 $ 2,512.41 $ 3,894.24 24.4 24.4 $ 174.88 $ 174.88

**Float Process Bending & Tempering Process**