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 System 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)

Item

Subsystem

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description

System

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)

Item

Subsystem

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description

System

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

SUBSYSTEM ROLL-UP 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

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 System D

11 Glass (Glazing), Frame, and Mechanism Subsystem

1 01

2 03

3 04

4 05

Item

Subsystem

System

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

DRAFT

Item

Subsystem

System

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 System D

11 Glass (Glazing), Frame, and Mechanism Subsystem

1 01

2 03

3 04

4 05

Item

Subsystem

System

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

DRAFT

Item

Subsystem

System

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 

Mass 

New 

Mass 

Base Glass 

Thickness (mm)

New Glass 

Thickness (mm) Base New Differential Percent Increase

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

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

Front Side Window 4.393 2.855 4.85 3.15 $31.43 $34.58 $3.15 10.0%

Rear Side Window 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%

Windshield - Inner Layer 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