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 Subsystem 776.46 94.56

3 03 Body System B 335.28 47.79

3 03 Body System C 52.07 2.04

3 03 Body System D 27.90 5.78

4 04 Suspension System 354.97 81.45

5 05 Driveline System 16.59 2.84

6 06 Brake System 104.58 29.27

7 07 Frame and Mounting System 70.04 10.19

8 09 Exhaust System 36.97 0.95

SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing 

Item

Vehicle

System

Sub-Subsystem Description

Technology Level: Variable Inlet & Exhaust Val

Vehicle Class: Sub-Compact Size Passenger Ve

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

9 10 Fuel System 46.98 5.97

10 11 Steering System 16.81 4.64

11 12 Climate Control 17.82 5.39

12 13 Info, Gage and Warning System 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 System 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 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

00 Vehicle

1 01 Engine

2 02 Transmission

3 03 Body Subsystem

3 03 Body System B

3 03 Body System C

3 03 Body System D

4 04 Suspension System

5 05 Driveline System

6 06 Brake System

7 07 Frame and Mounting System

8 09 Exhaust System

Item

Vehicle

System

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 GENERAL PART INFORMATION:

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 System

10 11 Steering System

11 12 Climate Control

12 13 Info, Gage and Warning System

13 14 Electrical Power Supply

14 15 In-Vehicle Entertainment

15 17 Lighting

16 18 Electrical Distribution and Electronic Control System

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 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

00 Vehicle

1 01 Engine

2 02 Transmission

3 03 Body Subsystem

3 03 Body System B

3 03 Body System C

3 03 Body System D

4 04 Suspension System

5 05 Driveline System

6 06 Brake System

7 07 Frame and Mounting System

8 09 Exhaust System

Item

Vehicle

System

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 GENERAL PART I

9 10 Fuel System

10 11 Steering System

11 12 Climate Control

12 13 Info, Gage and Warning System

13 14 Electrical Power Supply

14 15 In-Vehicle Entertainment

15 17 Lighting

16 18 Electrical Distribution and Electronic Control System

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 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

00 Vehicle

1 01 Engine

2 02 Transmission

3 03 Body Subsystem

3 03 Body System B

3 03 Body System C

3 03 Body System D

4 04 Suspension System

5 05 Driveline System

6 06 Brake System

7 07 Frame and Mounting System

8 09 Exhaust System

Item

Vehicle

System

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 GENERAL PART INFORMATION:

9 10 Fuel System

10 11 Steering System

11 12 Climate Control

12 13 Info, Gage and Warning System

13 14 Electrical Power Supply

14 15 In-Vehicle Entertainment

15 17 Lighting

16 18 Electrical Distribution and Electronic Control System

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 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

00 Vehicle

1 01 Engine

2 02 Transmission

3 03 Body Subsystem

3 03 Body System B

3 03 Body System C

3 03 Body System D

4 04 Suspension System

5 05 Driveline System

6 06 Brake System

7 07 Frame and Mounting System

8 09 Exhaust System

Item

Vehicle

System

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

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

9 10 Fuel System

10 11 Steering System

11 12 Climate Control

12 13 Info, Gage and Warning System

13 14 Electrical Power Supply

14 15 In-Vehicle Entertainment

15 17 Lighting

16 18 Electrical Distribution and Electronic Control System

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 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

00 Vehicle

1 01 Engine

2 02 Transmission

3 03 Body Subsystem

3 03 Body System B

3 03 Body System C

3 03 Body System D

4 04 Suspension System

5 05 Driveline System

6 06 Brake System

7 07 Frame and Mounting System

8 09 Exhaust System

Item

Vehicle

System

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)

NEW TECHNOLOGY PACKAGE

System 

ED&T/R&D

(x1000)

Tooling (x1000)

9 10 Fuel System

10 11 Steering System

11 12 Climate Control

12 13 Info, Gage and Warning System

13 14 Electrical Power Supply

14 15 In-Vehicle Entertainment

15 17 Lighting

16 18 Electrical Distribution and Electronic Control System

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 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411