### 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



### USD **USD** 

# 00 **Vehicle**

1 **01 Engine**  **618.29 41.94** 



### 2 **02 Transmission**  **261.26 19.48** 



### 3 **03 Body** 

**Subsy stem**  **776.46 94.56** 



### 3 **03 Body** 

**Sy stem B**  **335.28 47.79** 



### 3 **03 Body** 

**Sy stem C**  **52.07 2.04** 



### 3 **03 Body** 

**Sy stem D**  **27.90 5.78** 



### 4 **04 Suspension Sy**  **stem 354.97**  **81.45**



### 5 **05 Driveline Sy**  **stem 16.59**  **2.84**



### 6 **06 Brake Sy**  **stem 104.58**  **29.27**



### 7 **07 Frame and Mounting Sy**  **stem 70.04**  **10.19**



### 8 **09 Exhaust Sy**  **stem 36.97**  **0.95**



# SYSTEM & SUBSYSTEM DESCRIPTION

ManufacturingItemVehicleSystem 

### Sub-Subsystem Description 

# Technology **Level:** Variable Inlet & Exhaust Valve Timing (Solenoid Controlled) **Vehicle Class:** Sub

- Compact Size Passenger Vehicle, 3 

# Study Case#: N0200 (N=New, 02=Multi

9 **10 Fuel Sy**  **stem 46.98**  **5.97**



### 10 **11 Steering Sy**  **stem 16.81**  **4.64**



### 11 **12 Climate Control**  **17.82 5.39** 



### 12 **13 Info, Gage and Warning Sy**  **stem 1.70**  **0.05**



### 13 **14 Electrical Power Supply** 

**- -** 



### 14 **15 In-Vehicle Entertainment**  **1.26 0.64** 



### 15 **17 Lighting**  **10.87 1.23** 



### 16 **18 Electrical Distribution and Electronic Control Sy**  **stem 7.61**  **0.62**



### 17 **19 Electronic Features** 

**- -** 



### 2,757.46 **354.84**

**Note: "+" = cost decrease, "-" = cost increase**  **SUBSYSTEM ROLL-UP**

EPA-HQ-OAR-2010-0799-DRAFT-41848.xls
EPA Contract:EP-C-07-069 W A1-3 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



# 00 **Vehicle**

1 **01 Engine** 

2 **02 Transmission** 

3 **03 Body** 

**Subsy stem** 

3 **03 Body** 

**Sy stem B** 

3 **03 Body** 

**Sy stem C** 

3 **03 Body** 

**Sy stem D** 

4 **04 Suspension Sy**  **stem**

5 **05 Driveline Sy**  **stem**

6 **06 Brake Sy**  **stem**

7 **07 Frame and Mounting Sy**  **stem**

8 **09 Exhaust Sy**  **stem**ItemVehicleSystem

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



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

**123.85 784.08**  **5.88 23.78**  **20.43 6.48**  **56.57 0**  **840.65**

**33.32 314.05**  **2.20 28.98**  **20.12 3.30**  **54.61 0**  **368.66**

**-**

**490.66 1,369.63**  **0.02 0.35**  **0.28 0.06**  **0.70 0**  **1,363.56**

**-**

**111.10 494.18**  **1.77 29.86**  **22.55 6.13**  **60.31 0**  **554.49**

**-**

**8.24 62.35**  **0.44 6.84**  **5.52 1.11**  **13.90 0**  **76.25**

**-**

**114.79 148.48**  **0.38 7.59**  **5.09 1.26**  **14.33 0**  **162.81**

**-**

**110.32 546.73**  **4.80 43.36**  **34.25 9.37**  **91.78 0**  **638.51**

**-**

**5.87 25.30**  **0.34 2.61**  **2.57 0.95**  **6.47 0**  **31.77**

**-**

**73.30 207.15**  **1.06 15.50**  **13.08 3.99**  **33.64 0**  **240.79**

**-**

**41.52 121.75**  **0.82 8.54**  **9.40 4.30**  **23.05 0**  **144.80**

**-**

**0.97 38.88**  **0.12 1.57**  **1.45 0.60**  **3.74 0**  **42.62**

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

**Packaging**
**Cost (Component/**  **Assembly)** Markup **Net Component/**  **Assembly Cost Impact to** 
**OEM Total**  **Manufacturing**
**Cost (Component/**  **Assembly)** 

# NEW TECHNOLOGY GENERA **L PA RT INFORMA**  **TION:** Variable Inlet & Exhaust Valve Timing (Solenoid Controlled) Compact Size Passenger Vehicle, 3

- 4 Passengers N0200 (N=New, 02=Multi

- Air, 00 =Subcompact Vehicle Class)

9 **10 Fuel Sy**  **stem**

10 **11 Steering Sy**  **stem**

11 **12 Climate Control** 

12 **13 Info, Gage and Warning Sy**  **stem**

13 **14 Electrical Power Supply** 

14 **15 In-Vehicle Entertainment** 

15 **17 Lighting** 

16 **18 Electrical Distribution and Electronic Control Sy**  **stem**

17 **19 Electronic Features** 

**Note: 17.74**  **70.69 0.48**  **5.28 5.61**  **2.47 13.84**  **0 84.54** 

**-**

**5.57 27.03**  **0.20 1.35**  **1.15 0.34**  **3.04 0**  **30.07**

**-**

**3.97 27.17**  **0.07 1.38**  **0.92 0.23**  **2.61 0**  **29.78**

**-**

**0.31 2.07**  **0.01 0.12**  **0.14 0.07**  **0.34 0**  **2.41**

**-**

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

**0.78 2.67**  **0.01 0.27**  **0.18 0.02**  **0.49 0**  **3.16**

**-**

**3.31 15.41**  **0.04 0.77**  **0.52 0.13**  **1.46 0**  **16.87**

**-**

**0.58 8.82**  **0.03 0.45**  **0.34 0.05**  **0.87 0**  **9.69**

**-**

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



### 1,146.19 **4,266.44 18.67**  **178.61 143.59**  **40.87 381.74**  **0 4,641.41** 

**-**



### EPA-HQ-OAR-2010-0799-DRAFT-41848.xls
EPA Contract:EP-C-07-069 W A1-3 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



# 00 **Vehicle**

1 **01 Engine** 

2 **02 Transmission** 

3 **03 Body** 

**Subsy stem** 

3 **03 Body** 

**Sy stem B** 

3 **03 Body** 

**Sy stem C** 

3 **03 Body** 

**Sy stem D** 

4 **04 Suspension Sy**  **stem**

5 **05 Driveline Sy**  **stem**

6 **06 Brake Sy**  **stem**

7 **07 Frame and Mounting Sy**  **stem**

8 **09 Exhaust Sy**  **stem**ItemVehicleSystem

Material Labor Burden End Item Scrap SG&A Profit



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

**36,537.30**

**- 653.53**  **41.76 119.55**  **814.84 5.61**  **26.47 22.62** 

**11,487.50**

**- 166.53**  **24.32 30.33**  **221.17 1.03**  **17.98 12.23** 

**33,000.00**

**- 600.48**  **87.33 446.34**  **1,134.15 0.02**  **0.37 0.29** 

**16,181.40**

**- 356.01**  **99.03 146.46**  **601.50 2.30**  **35.83 28.69** 

**- -**  **57.02 2.27**  **9.30 68.59**  **0.40 7.56**  **6.00**

**- -**  **25.76 6.44**  **102.31 134.50**  **0.35 6.91**  **4.64**

**15,871.24**

**- 429.10**  **103.60 137.94**  **670.63 5.96**  **53.36 41.94** 

**801.66**

**- 16.79**  **2.52 5.96**  **25.26 0.29**  **2.54 2.55** 

**12,858.77**

**- 157.80**  **52.09 143.38**  **353.27 1.77**  **27.10 21.98** 

**11,411.00**

**- 73.90**  **21.22 17.43**  **112.55 0.97**  **12.32 11.61** 

**- -**  **39.02 0.84**  **1.05 40.90**  **0.13 1.75**  **1.62 Tooling (x1000)**  **Investment (X1000)**  Manufacturing **Total Manufacturing** 
**Cost (Component/**  **Assembly)** Markup



# BASE TECHNOLOGY GENERA **L PA RT INFORMA**  **TION:**

9 **10 Fuel Sy**  **stem**

10 **11 Steering Sy**  **stem**

11 **12 Climate Control** 

12 **13 Info, Gage and Warning Sy**  **stem**

13 **14 Electrical Power Supply** 

14 **15 In-Vehicle Entertainment** 

15 **17 Lighting** 

16 **18 Electrical Distribution and Electronic Control Sy**  **stem**

17 **19 Electronic Features** 

**Note: 3,565.70** 

**- 28.66**  **12.35 32.53**  **73.54 0.51**  **5.83 6.01** 

**3,015.40**

**- 18.48**  **7.84 8.86**  **35.18 0.38**  **2.69 2.28** 

**684.00**

**- 18.12**  **4.37 13.20**  **35.70 0.09**  **1.81 1.21** 

**- -**  **1.95 0.06**  **0.22 2.23**  **0.01 0.13**  **0.15**

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

**216.70**

**- 1.46**  **1.55 1.62**  **4.62 0.04**  **0.48 0.32** 

**- -**  **7.91 2.26**  **4.55 14.72**  **0.04 0.74**  **0.49**

**210.00**

**- 8.92**  **0.59 0.63**  **10.14 0.03**  **0.51 0.34** 

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

**145,840.67**

**- 0**  

### 2,661.43 **470.43 1,221.64**  **4,353.50 19.96**  **204.39 164.98** 

EPA-HQ-OAR-2010-0799-DRAFT-41848.xls
EPA Contract:EP-C-07-069 W A1-3 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



# 00 **Vehicle**

1 **01 Engine** 

2 **02 Transmission** 

3 **03 Body** 

**Subsy stem** 

3 **03 Body** 

**Sy stem B** 

3 **03 Body** 

**Sy stem C** 

3 **03 Body** 

**Sy stem D** 

4 **04 Suspension Sy**  **stem**

5 **05 Driveline Sy**  **stem**

6 **06 Brake Sy**  **stem**

7 **07 Frame and Mounting Sy**  **stem**

8 **09 Exhaust Sy**  **stem**ItemVehicleSystem

ED&T-R&D Material



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

**6.94 61.65**  **0 876.49** 

**- 42,429.50** 

**- 35.24** 

**2.09 33.34**  **0 254.51** 

**- 3,836.70** 

**- (94.73)** 

**0.06 0.74**  **0 1,136.11** 

**- 10,100.00** 

**- (175.99)** 

**9.15 75.97**  **0 677.47** 

**- 26,147.55** 

**- 20.73** 

**1.21 15.18**  **0 83.77** 

**- -**  **- 4.95** 

**1.15 13.05**  **0 147.56** 

**- -**  **- (2.15)** 

**11.32 112.58**  **0 783.22** 

**- 8,326.87** 

**- 74.13** 

**0.97 6.34**  **0 31.60** 

**- 115.80** 

**- 0.19** 

**6.23 57.08**  **0 410.35** 

**- 11,432.64** 

**- 53.22** 

**4.07 28.97**  **0 141.52** 

**- 7,710.61** 

**- 3.86** 

**0.67 4.18**  **0 45.08** 

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

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

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

# BASE TECHNOLOGY GENERA **L PA RT INFORMA**  **TION:**

9 **10 Fuel Sy**  **stem**

10 **11 Steering Sy**  **stem**

11 **12 Climate Control** 

12 **13 Info, Gage and Warning Sy**  **stem**

13 **14 Electrical Power Supply** 

14 **15 In-Vehicle Entertainment** 

15 **17 Lighting** 

16 **18 Electrical Distribution and Electronic Control Sy**  **stem**

17 **19 Electronic Features** 

**Note: 2.55**  **14.91 0**  **88.45**

**- 5,191.00** 

**- (18.32)** 

**0.59 5.94**  **0 41.11** 

**- 4,368.10** 

**- 1.67** 

**0.30 3.42**  **0 39.11** 

**- 1,070.00** 

**- 0.30** 

**0.07 0.37**  **0 2.60** 

**- -**  **- 0.25** 

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

**0.04 0.89**  **0 5.52** 

**- 1,392.30** 

**- 0.20** 

**0.12 1.39**  **0 16.11** 

**- 400.00** 

**- (2.95)** 

**0.03 0.90**  **0 11.04** 

**- 313.50** 

**- 1.31** 

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



### 47.58 **436.90 0**  **4,791.63**

**- 122,834.57** 

**-** 

### (96.03)

EPA-HQ-OAR-2010-0799-DRAFT-41848.xls
EPA Contract:EP-C-07-069 W A1-3 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



# 00 **Vehicle**

1 **01 Engine** 

2 **02 Transmission** 

3 **03 Body** 

**Subsy stem** 

3 **03 Body** 

**Sy stem B** 

3 **03 Body** 

**Sy stem C** 

3 **03 Body** 

**Sy stem D** 

4 **04 Suspension Sy**  **stem**

5 **05 Driveline Sy**  **stem**

6 **06 Brake Sy**  **stem**

7 **07 Frame and Mounting Sy**  **stem**

8 **09 Exhaust Sy**  **stem**ItemVehicleSystem

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



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

**(0.18) (4.30)**  **30.76 (0.26)**  **2.69 2.19**  **0.47 5.08**  **0 35.84** 

**4.84 (2.99)**  **(92.88) (1.16)**  **(11.00) (7.89)**  **(1.21) (21.26)**  **0 (114.15)** 

**(7.23) (44.32)**  **(235.49) 0.00**  **0.02 0.02**  **0.00 0.04**  **0 (227.45)** 

**51.24 35.35**  **107.32 0.53**  **5.97 6.14**  **3.02 15.66**  **0 122.98** 

**0.23 1.06**  **6.24 (0.03)**  **0.72 0.48**  **0.11 1.27**  **0 7.52** 

**0.66 (12.48)**  **(13.97) (0.03)**  **(0.68) (0.45)**  **(0.11) (1.28)**  **0 (15.25)** 

**22.15 27.62**  **123.91 1.16**  **10.00 7.69**  **1.95 20.80**  **0 144.71** 

**(0.32) 0.09**  **(0.04) (0.05)**  **(0.07) (0.02)**  **0.01 (0.13)**  **0 (0.16)** 

**22.81 70.08**  **146.12 0.70**  **11.60 8.90**  **2.24 23.44**  **0 169.56** 

**11.03 (24.09)**  **(9.20) 0.16**  **3.79 2.21**  **(0.23) 5.92**  **0 (3.28)** 

**(0.11) 0.08**  **2.02 0.01**  **0.19 0.17**  **0.07 0.44**  **0 2.47**  **Total Markup**
**Cost (Component/**  **Assembly) Total** 

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

# INCREMENTA **L COST TO UPGRA DE TO NEW TECHNOLOGY PA**  **CKAGE**

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



### 9 **10 Fuel Sy**  **stem**

10 **11 Steering Sy**  **stem**

11 **12 Climate Control** 

12 **13 Info, Gage and Warning Sy**  **stem**

13 **14 Electrical Power Supply** 

14 **15 In-Vehicle Entertainment** 

15 **17 Lighting** 

16 **18 Electrical Distribution and Electronic Control Sy**  **stem**

17 **19 Electronic Features** 

**Note: 6.38**  **14.79 2.85**  **0.03 0.55**  **0.40 0.08**  **1.06 0**  **3.91**

**3.19 3.28**  **8.15 0.18**  **1.34 1.13**  **0.25 2.90**  **0 11.05** 

**(1.01) 9.24**  **8.53 0.02**  **0.43 0.29**  **0.07 0.81**  **0 9.34** 

**0.01 (0.09)**  **0.16 0.00**  **0.01 0.01**  **0.01 0.03**  **0 0.19** 

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

**0.91 0.84**  **1.95 0.03**  **0.21 0.14**  **0.02 0.40**  **0 2.35** 

**1.03 1.24**  **(0.69) (0.00)**  **(0.03) (0.02)**  **(0.01) (0.07)**  **0 (0.76)** 

**(0.03) 0.04**  **1.32 (0.00)**  **0.06 0.00**  **(0.03) 0.03**  **0 1.35** 

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



### 115.59 **75.44 87.06**  **1.28 25.79**  **21.38 6.71**  **55.16 0**  **150.21**

EPA-HQ-OAR-2010-0799-DRAFT-41848.xls
EPA Contract:EP-C-07-069 W A1-3 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



# 00 **Vehicle**

1 **01 Engine** 

2 **02 Transmission** 

3 **03 Body** 

**Subsy stem** 

3 **03 Body** 

**Sy stem B** 

3 **03 Body** 

**Sy stem C** 

3 **03 Body** 

**Sy stem D** 

4 **04 Suspension Sy**  **stem**

5 **05 Driveline Sy**  **stem**

6 **06 Brake Sy**  **stem**

7 **07 Frame and Mounting Sy**  **stem**

8 **09 Exhaust Sy**  **stem**ItemVehicleSystem



### USD **USD USD** 

**- 5,892.20** 

**-**

**- (7,650.80)** 

**-**

**- (22,900.00)** 

**-**

**- 9,966.15** 

**-**

**- 0.00** 

**-**

**- 0.00** 

**-**

**- (7,544.37)** 

**-**

**- (685.86)** 

**-**

**- (1,426.12)** 

**-**

**- (3,700.39)** 

**-**

**- 0.00** 

**- Investment**  **(X1000)** 

# INCREMENTA **L COST TO UPGRA DE TO NEW TECHNOLOGY PA**  **CKAGE**

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



### 9 **10 Fuel Sy**  **stem**

10 **11 Steering Sy**  **stem**

11 **12 Climate Control** 

12 **13 Info, Gage and Warning Sy**  **stem**

13 **14 Electrical Power Supply** 

14 **15 In-Vehicle Entertainment** 

15 **17 Lighting** 

16 **18 Electrical Distribution and Electronic Control Sy**  **stem**

17 **19 Electronic Features** 

**Note: -**  **1,625.30**

**-**

**- 1,352.70** 

**-**

**- 386.00** 

**-**

**- 0.00** 

**-**

**- -**  **-**

**- 1,175.60** 

**-**

**- 400.00** 

**-**

**- 103.50** 

**-**

**- -**  **-**

**- (23,006.09)** 

**-**



### EPA-HQ-OAR-2010-0799-DRAFT-41848.xls
EPA Contract:EP-C-07-069 W A1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411