### Page:1 of 6 

# 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



# 030600 Sound and Heat Control Subsy **stem (Body )** 

1 **00 Assembly of Sound and Heat Control Subsystem (Body)** 

**- $** 

**-**

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### 2 **01 Rear Seating Battery Area**  **5.21 $**  **3.10**

**$ 1.66** 

**$ 9.98** 

**$ 0.08** 

**$ 1.05** 

**$ 0.97** 

**$ 0.32** 

**$ 2.42** 

**$ 0.17** 

**$ 12.57** 

**$**

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**-**

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### 3 **02 TBD** 

**- $** 

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### 4 **03 Heat Insulation Shields - Engine Bay & Underfloor** 

**- $** 

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### 5 **04 Noise Insulation, Engine Bay and Underfloor** 

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**$** Markup **Net**

**Component/**

**Assembly**

**Cost Impact to**

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**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)** Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**ItemSubsystem 

### System

**ED&T/R&D**

**(x1000)** 

### 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) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **Technology Level:**  Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

6 **05 Engine Compartment Trim / E-Box** 

**- $** 

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### 7 **10 TBD** 

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### 9 **70 Pipes, Hoses, Ducting** 

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### 10 **75 Brackets** 

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### 11 **80 Boltings** 

**- $** 

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### 12 **85 Sealing Elements** 

**- $** 

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### 13 **90 Bearings Elements Misc** 

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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 6 

# 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

Markup **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)** Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**ItemSubsystem 

### System

**ED&T/R&D**

**(x1000)** 

### 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) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **Technology Level:**  Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

**5.21 $**  **3.10**

**$ 1.66** 

**$ 9.98** 

**$ 0.08** 

**$ 1.05** 

**$ 0.97** 

**$ 0.32** 

**$ 2.42** 

**$ 0.17** 

**$ 12.57** 

**$**

**-**

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**-**

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### -

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**-**

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**$ 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 6 

# COST MODEL ANALYSIS TEMPLATE
**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/23/2012

DRAFT



# 030600 Sound and Heat Control Subsy **stem (Body )** 

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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**Cost**

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**Assembly) Total** 

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**Cost**

**(Component**

**/ Assembly) Net** 

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**Assembly**

**Cost Impact to**

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**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(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** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

6 **05**

7 **10**

8 **15**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

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### 0 **0**

**-**

**$**

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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 6 

# 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 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) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(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** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 5.21

**$ 3.10** 

**$ 1.66** 

**$ 9.98** 

**$ 0.08** 

**$ 1.05** 

**$ 0.97** 

**$ 0.32** 

**$ 2.42** 

**$ 0.17** 

**$ 12.57** 

**$**

**-**

**$**

**-**

**$**



### 09000064810ec171.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: 8/23/2012

DRAFT



# 030600 Sound and Heat Control Subsy **stem (Body )** 

1 **00**

2 **01**

3 **02**

4 **03**

5 **04**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**- $** 

**- $** 

**- $** 

**- $** 

**- $**  **Investment(X1**

**000)**



### 6 **05**

7 **10**

8 **15**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0 -** 

**$**

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 



### 0 **0**

**-**

**$**



### 09000064810ec171.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: 8/23/2012

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:1 of 4 

# 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



### 0

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 030600 Sound and Heat Control Subsy **stem (Body )** 

1 **00 Assembly of Sound and Heat Control Subsystem (Body)** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 2 **01 Rear Seating Battery Area**  **5.21 $**  **3.10**

**$ 1.66** 

**$ 9.98** 

**$ 0.08** 

**$ 1.05** 

**$ 0.97** 

**$ 0.32** 

**$ 2.42** 

**$ 0.17** 

**$ 12.57** 

**$**

**-**

**$**



### H Duct & Shield Rear Seat to Battery Asm 03 06 01

- N0502

- 00 1 Full 1 0.18 $ 0.97

$ 0.38

$ **1.53**

**$** 0.01

$ 0.10

$ 0.09

$ 0.04

$ **0.24**

**$** 0.17

$ **1.94**

**$**

**-**

**$**



### H Duct & Shield Rear Seat to Battery A 03 06 01

- N0502

- 01 1 Full 1 2.50 $ 1.10

$ 0.75

$ **4.35**

**$** 0.04

$ 0.56

$ 0.51

$ 0.16

$ **1.27**

**$**

-

$ **5.62**

**$**

**-**

**$**



### H Duct Rear Seat to Battery Access Door Asm B 03 06 01

- N0502

- 02 1 Full 1 0.30 $ 0.34

$ 0.17

$ **0.80**

**$** 0.01

$ 0.11

$ 0.10

$ 0.03

$ **0.24**

**$**

-

$ **1.04**

**$**

**-**

**$**Sub-Subsystem



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponent 

### System

**ED&T/R&D**

**(x1000)** 

# 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 Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

H Duct Rear Seat to Battery Access Door Asm B 03 06 01

- N0502

- 02 1 Full 1 0.30 $ 0.34

$ 0.17

$ **0.80**

**$** 0.01

$ 0.11

$ 0.10

$ 0.03

$ **0.24**

**$**

-

$ **1.04**

**$**

**-**

**$**



### H Insulation Rear Seat Pan with Clips C 03 06 01

- N0502

- 03 1 Full 1 2.23 $ 0.69

$ 0.37

$ **3.29**

**$** 0.02

$ 0.29

$ 0.27

$ 0.09

$ **0.67**

**$**

-

$ **3.97**

**$**

**-**

**$**



### 3 **02 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 4 **03 Heat Insulation Shields - Engine Bay & Underfloor** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5 **04 Noise Insulation, Engine Bay and Underfloor** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 6 **05 Engine Compartment Trim / E-Box** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **15 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 9 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 10 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### Boltings **$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $** 



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 4 

# 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&DSub-Subsystem



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponent 

### System

**ED&T/R&D**

**(x1000)** 

# 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 Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5.21 $ 3.10

$ 1.66

$ **9.98**

**$** 0.08

$ 1.05

$ 0.97

$ 0.32

$ **2.42**

**$** 0.17

$ **12.57**

**$**

**-**

**$** 

### Complete Subsystem Quote

(Yes/No) 

## No

**NOTES:**



## 1. **= 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** (Yes/No)

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:3 of 4 

# COST MODEL ANALYSIS TEMPLATE
**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/23/2012

DRAFT

0



# 030600 Sound and Heat Control Subsy **stem (Body )** 

1 **00 Assembly of Sound and Heat Control Subsystem (Body)** 

2 **01 Rear Seating Battery Area** 

H Duct & Shield Rear Seat to Battery Asm 03 06 01

- N0502

- 00 1 Full 1

H Duct & Shield Rear Seat to Battery A 03 06 01

- N0502

- 01 1 Full 1

H Duct Rear Seat to Battery Access Door Asm B 03 06 01

- N0502

- 02 1 Full 1Sub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# 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 Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1) 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment** 

**(X1000) Tooling** 

**(x1000)**



### H Duct Rear Seat to Battery Access Door Asm B 03 06 01

- N0502

- 02 1 Full 1

H Insulation Rear Seat Pan with Clips C 03 06 01

- N0502

- 03 1 Full 1

3 **02 TBD** 

4 **03 Heat Insulation Shields - Engine Bay & Underfloor** 

5 **04 Noise Insulation, Engine Bay and Underfloor** 

6 **05 Engine Compartment Trim / E-Box** 

7 **10 TBD** 

8 **15 TBD** 

9 **70 Pipes, Hoses, Ducting** 

10 **75 Brackets** 

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

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$** 

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



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE
**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/23/2012

DRAFTSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# 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 Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1) 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

12 **85 Sealing Elements** 

13 **90 Bearings Elements Misc** 

14 **99 Miscellaneous** 

Complete Subsystem Quote

(Yes/No) 

## No **Investment**

**(X1000) Tooling** 

**(x1000)**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### NOTES:



## 1. **= 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** (Yes/No)

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:1 of 4 

# 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



### 0

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 030600 Sound and Heat Control Subsy **stem (Body )** 

1 **00 Assembly of Sound and Heat Control Subsystem (Body)** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 2 **01 Rear Seating Battery Area** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 3 **02 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000)** Markup **Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1) 

# BASE 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 Vehilce, 4

- 6 Passengers 

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

4 **03 Heat Insulation Shields - Engine Bay & Underfloor** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 5 **04 Noise Insulation, Engine Bay and Underfloor** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 6 **05 Engine Compartment Trim / E-Box** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **15 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 9 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 10 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 4 

# 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 **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000)** Markup **Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1) 

# BASE 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 Vehilce, 4

- 6 Passengers 

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

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### NOTES:



## 1. Complete Subsystem Quote

(Yes/No) 

## N

**= 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:3 of 4 

# COST MODEL ANALYSIS TEMPLATE
**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/23/2012

DRAFT

0



# 030600 Sound and Heat Control Subsy **stem (Body )** 

1 **00 Assembly of Sound and Heat Control Subsystem (Body)** 

2 **01 Rear Seating Battery Area** 

3 **02 TBD**  

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1)QTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment** 

**(X1000) Tooling** 

**(x1000)**



### 4 **03 Heat Insulation Shields - Engine Bay & Underfloor** 

5 **04 Noise Insulation, Engine Bay and Underfloor** 

6 **05 Engine Compartment Trim / E-Box** 

7 **10 TBD** 

8 **15 TBD** 

9 **70 Pipes, Hoses, Ducting** 

10 **75 Brackets** 

11 **80 Boltings** 

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

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**



### 09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE
**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/23/2012

DRAFT



# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor
(Default =1)QTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

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

**NOTES:**



## 1. Complete Subsystem Quote

(Yes/No) 

## N

**= 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 Investment** 

**(X1000) Tooling** 

**(x1000)**

**- $** 

**-**

**$**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 Duct & Shield Rr Seat Asm: Duct & Nuts 030601-N05020-01 **1** Assemble Duct to Rr Seat w/

Nuts OEM Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **153 2**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.50**  **$0.20 $0.70**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.70 $0.70**  **$0.00**

2 Duct & Shield Rr Seat Asm: Battery Access

Door & Label on Access Door 030601-N05020-02 **1** Assemble HV Cable Asm

through duct opening & snap

together access door to duct;

Apply label to door OEM Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **171 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.22**  **$0.09 $0.31**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.31 $0.31**  **$0.00**

3 Duct & Shield Rr Seat Asm: Pan Shield w/ Clips 030601-N05020-03 **1** Assemble Pan Shield to vehicle

body panels OEM Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **157 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.25**  **$0.10 $0.34**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.34 $0.34**  **$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** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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)**

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**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 **0 #####**  **0 2**  **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 2**  **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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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)**

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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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 H Nut Rear Seat to Battery Duct 030601-N05020-04 **4** S **$0.00** $0.02 **$0.00 $0.08**  **$0.08**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 H Label Battery Access Door 030601-N05020-05 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

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** 

### "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 8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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**

**$0.18**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total**

**Mark-up $1.53** 

**T1 or OEM Total Manufacturing Cost: $0.18**  **$0.97 $0.38**  **$1.53 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.53** 

### "Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.

**3 1** 



### Notes: **T1 or OEM Total Manufacturing Cost: $0.18**  **$0.97 $0.38**  **$1.53 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.53**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.10**  **$0.09 $0.04**  **$0.24**

**Base Cost Impact to Vehicle: $0.18**  **$0.97 $0.38**  **$1.53 $0.01**  **$0.10 $0.09**  **$0.04 $0.24**  **$1.77 $0**  **$0**

**Packaging Cost: $0.17** 

**Net Cost Impact to Vehicle: $1.94**  

### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation
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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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: **$0.168 $335,160**  **0.00% 2,250,000**  **60 5.00%**  $280 **1197** 48 **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: Option #1

Part Size: 1000X200X100
Parts/Layer: 6 Number of Layers: 7 Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables 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: **$0.168** 

### 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)

Duct & Shield Rr Seat Asm: Duct & Nuts 030601-N05020-01

Duct & Shield Rr Seat Asm: Battery Access

Door & Label on Access Door 030601-N05020-02

Duct & Shield Rr Seat Asm: Pan Shield w/ Clips 030601-N05020-03



### 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** **c k** **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** 

**$0.50 $0.20**  **$0.70 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Assemble Duct to Rear Seat Asm with Nuts (2x & 2x) using power tool assist **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 59 1 1 47 **1.0 2.0** 

**$0.22 $0.09**  **$0.31 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Assemble HV Cable asm through Duct opening; snap together access door on duct body; Apply Label to

Access Door **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 21 1 1 21 **1.0 1.0** 

**$0.25 $0.10**  **$0.34 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Assemble Pan shield to vehicle body panels (2x & 2x) w/ Xmas clips & push in place **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 23 1 1 23 **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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



## 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**  Assemble Duct to Rear Seat Asm with Nuts (2x & 2x) using power tool assist **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 2.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Assemble HV Cable asm through Duct opening; snap together access door on duct body; Apply Label to

Access Door **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**  Assemble Pan shield to vehicle body panels (2x & 2x) w/ Xmas clips & push in place **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 2.0** 

**$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** **c k** **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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$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** 

**$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)

H Nut Rear Seat to Battery Duct 030601-N05020-04

H Label Battery Access Door 030601-N05020-05 

### 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** **c k** **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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.08**

**$0.00**

**$0.10**

**$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**

**$0.97 $0.38**  **$1.53 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.53 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** **c k** **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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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)

Duct & Shield Rr Seat Asm: Duct & Nuts 030601-N05020-01

Duct & Shield Rr Seat Asm: Battery Access

Door & Label on Access Door 030601-N05020-02

Duct & Shield Rr Seat Asm: Pan Shield w/ Clips 030601-N05020-03



### 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** 

**153 23.50**  2.00

**171 21.00**  1.00

**157 23.00**  1.00

**#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!** 

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**#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!** 

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**#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: 11 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)

H Nut Rear Seat to Battery Duct 030601-N05020-04

H Label Battery Access Door 030601-N05020-05**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

### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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**

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** 

### 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)**

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 Duct & Shield Rr Seat: Foam Seal-480; Foam

Seal-630 & Push Pins 030601-N05020-06 **1** Assemble Foam Seal strips to

Duct body & push together

push pin connectors T2/T3 Mech. Assembly, MSMC Not Applicable General Assembly Mech Assembly, LC, Base **114 2**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.67**  **$0.26 $0.94**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.13**  **$1.07 $1.07**  **$0.00**

2 Duct & Shield Rr Seat: Foam Seal-900 & Foam 030601-N05020-07 **1** Assemble Foam Seal strips to T2/T3 Mech. Assembly, MSMC Not Applicable General Assembly Mech Assembly, LC, Base **112 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.34**  **$0.13 $0.48**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.07**  **$0.54 $0.54**  **$0.00** 2 Duct & Shield Rr Seat: Foam Seal-900 & Foam

Seal-50 030601-N05020-07 **1** Assemble Foam Seal strips to

Duct body T2/T3 Mech. Assembly, MSMC Not Applicable General Assembly Mech Assembly, LC, Base **112 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.34**  **$0.13 $0.48**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.07**  **$0.54 $0.54**  **$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 2**  **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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

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 H Duct & Shield Rear Seat 030601-N05020-08 **1** Mold T2/T3 Inject. Mold, MSMC HD Polypro Mold/Cast/Sinter Operator Inject. Mold, MLS **257 0.5**  **1 1**  2.117 **$0.87 $41.48**  **$90.59 $90.59**  **$1.84 $0.08**  **$0.35 $2.27**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.32**  **$2.59 $2.59**  **$1.84**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 H Nut Rear Seat to Battery Duct 030601-N05020-09 **4** S **$0.00** $0.02 **$0.00 $0.08**  **$0.08**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 H Label Battery Access Door 030601-N05020-09 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 H Foam Seal, Duct, 480mm (18.9") 030601-N05020-10 **1** S **$0.00** $0.09 **$0.00 $0.09**  **$0.09**

6 H Foam Seal, Duct, 630mm (24.8") 030601-N05020-11 **1** S **$0.00** $0.12 **$0.00 $0.12**  **$0.12**

7 H Push Pin Duct Rear Seat to Battery Molded

Foam S 030601-N05020-12 **4** S **$0.00** $0.02 **$0.00 $0.08**  **$0.08**

8 H Foam Seal, Duct, 900mm (35.4") 030601-N05020-13 **1** S **$0.00** $0.18 **$0.00 $0.18**  **$0.18** 

### "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. 8 H Foam Seal, Duct, 900mm (35.4") 030601-N05020-13 **1** S **$0.00** $0.18 **$0.00 $0.18**  **$0.18**

9 H Foam Seal, Duct Access, 50mm(1.97") 030601-N05020-14 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

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**

**$2.50**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total**

**Mark-up $4.86** 

**T1 or OEM Total Manufacturing Cost: $2.50**  **$1.10 $0.75**  **$4.35 $0.02**  **$0.24 $0.22**  **$0.04 $0.52**  **$4.86** 

### Supplier for Subassembly.

**3 1** 



### Notes: **T1 or OEM Total Manufacturing Cost: $2.50**  **$1.10 $0.75**  **$4.35 $0.02**  **$0.24 $0.22**  **$0.04 $0.52**  **$4.86**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.02 $0.32**  **$0.29 $0.12**  **$0.75**

**Base Cost Impact to Vehicle: $2.50**  **$1.10 $0.75**  **$4.35 $0.04**  **$0.56 $0.51**  **$0.16 $1.27**  **$5.62 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $5.62**  

### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation
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: **T1 Moderate Assembly Complexity**


## 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: H Duct & Shield Rear Seat to Battery**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 Returnables 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** **c k** **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** 

**$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)

Duct & Shield Rr Seat: Foam Seal-480; Foam

Seal-630 & Push Pins 030601-N05020-06

Duct & Shield Rr Seat: Foam Seal-900 & Foam 030601-N05020-07 **$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** 

**$0.67 $0.26**  **$0.94 $0.00**  **$0.06 $0.06**  **$0.01 $0.13**  Assemble Foam Seal-480L & 630L strips to Duct body & push together push pin connectors (4x) **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 73 1 1 63 **1.0 2.0** 

**$0.34 $0.13**  **$0.48 $0.00**  **$0.03 $0.03**  **$0.00 $0.07**  Assemble Foam Seal-900L & 50L strips to Duct body **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 45 1 1 32 **1.0 1.0**  Duct & Shield Rr Seat: Foam Seal-900 & Foam

Seal-50 030601-N05020-07 **$0.34 $0.13**  **$0.48 $0.00**  **$0.03 $0.03**  **$0.00 $0.07**  Assemble Foam Seal-900L & 50L strips to Duct body **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 45 1 1 32 **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 2.0** 

**$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** **c k** **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** 

H Duct & Shield Rear Seat 030601-N05020-08



## 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** 

**$0.08 $0.35**  **$2.27 $0.01**  **$0.15 $0.14**  **$0.02 $0.32**  800-1500 Ton Injection Molding w/ 2 cavity mold for Duct Rear Seat to Battery; operator cycle controls **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 28 1 2 28 **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** 

**$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)

H Nut Rear Seat to Battery Duct 030601-N05020-09

H Label Battery Access Door 030601-N05020-09

H Foam Seal, Duct, 480mm (18.9") 030601-N05020-10

H Foam Seal, Duct, 630mm (24.8") 030601-N05020-11

H Push Pin Duct Rear Seat to Battery Molded

Foam S 030601-N05020-12

H Foam Seal, Duct, 900mm (35.4") 030601-N05020-13 

### 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** **c k** **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**

**$0.08**

**$0.00**

**$0.10**

**$0.00**

**$0.09**

**$0.12**

**$0.08**

**$0.18** H Foam Seal, Duct, 900mm (35.4") 030601-N05020-13

H Foam Seal, Duct Access, 50mm(1.97") 030601-N05020-14 **$0.01**

**$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**

**$1.10 $0.75**  **$4.35 $0.02**  **$0.24 $0.22**  **$0.04 $0.52** 

**$4.86 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** **c k** **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!** 

-

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

-

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

-

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

-



## Purchase Part - High Impact Item (Full Cost Mapping)

Duct & Shield Rr Seat: Foam Seal-480; Foam

Seal-630 & Push Pins 030601-N05020-06

Duct & Shield Rr Seat: Foam Seal-900 & Foam 030601-N05020-07 **#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!** 

-

**114 31.45**  2.00

**112 32.10**  1.00 Duct & Shield Rr Seat: Foam Seal-900 & Foam

Seal-50 030601-N05020-07 **112 32.10**  1.00

**#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!** 

-

H Duct & Shield Rear Seat 030601-N05020-08



## 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!** 

-

**257 14.00**  0.50

**#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: 11 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)

H Nut Rear Seat to Battery Duct 030601-N05020-09

H Label Battery Access Door 030601-N05020-09

H Foam Seal, Duct, 480mm (18.9") 030601-N05020-10

H Foam Seal, Duct, 630mm (24.8") 030601-N05020-11

H Push Pin Duct Rear Seat to Battery Molded

Foam S 030601-N05020-12

H Foam Seal, Duct, 900mm (35.4") 030601-N05020-13**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** 

H Foam Seal, Duct, 900mm (35.4") 030601-N05020-13

H Foam Seal, Duct Access, 50mm(1.97") 030601-N05020-14



### 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

### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct Rear Seat to Battery Access Door Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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**

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** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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)**

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 Duct Rr Seat Batt Acs Dr: Foam Seal-340 &

Foam Seal-50 030601-N05020-15 **1** Assemble Foam Seal strips to

Duct body T2/T3 Mech. Assembly, MSMC Not Applicable General Assembly Mech Assembly, LC, Base **120 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.32**  **$0.13 $0.45**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.06**  **$0.51 $0.51**  **$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 2**  **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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct Rear Seat to Battery Access Door Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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)**

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 H Duct Rear Seat Batt Access Door 030601-N05020-16 **1** Mold T2/T3 Inject. Mold, MSMC HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SMS **655 0.25**  **1 1**  0.248 **$0.87 $41.48**  **$28.80 $28.80**  **$0.22 $0.02**  **$0.04 $0.28**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.04**  **$0.31 $0.31**  **$0.22**



### 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**



### 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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Duct Rear Seat to Battery Access Door Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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)**

1 H Duct Rear Seat to Battery Access Door Seal

340 030601-N05020-17 **1** S **$0.00** $0.07 **$0.00 $0.07**  **$0.07**

2 H Duct Rear Seat to Battery Access Door Small

Seal 50 030601-N05020-18 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

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**

**$0.30**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total**

**Mark-up $0.90** 

**T1 or OEM Total Manufacturing Cost: $0.30**  **$0.34 $0.17**  **$0.80 $0.00**  **$0.05 $0.04**  **$0.01 $0.10**  **$0.90**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **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:** 

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.06**  **$0.05 $0.02**  **$0.14**

**Base Cost Impact to Vehicle: $0.30**  **$0.34 $0.17**  **$0.80 $0.01**  **$0.11 $0.10**  **$0.03 $0.24**  **$1.04 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.04**  **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation
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: **T1 Moderate Assembly Complexity**


## 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: H Duct Rear Seat to Battery Access Door Asm**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 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 Returnables 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** **c k** **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** 

**$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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



## Purchase Part - High Impact Item (Full Cost Mapping)

Duct Rr Seat Batt Acs Dr: Foam Seal-340 &

Foam Seal-50 030601-N05020-15 **$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** 

**$0.32 $0.13**  **$0.45 $0.00**  **$0.03 $0.03**  **$0.00 $0.06**  Assemble Foam Seal-380L & 50L strips to Battery Access Door **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 30 1 1 30 **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 2.0**  **#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** 

**$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** **c k** **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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$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** 

H Duct Rear Seat Batt Access Door 030601-N05020-16



## 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** 

**$0.02 $0.04**  **$0.28 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  200-400 Ton Injection Molding w/ 4 cavity mold for Duct Rear Seat Battery Access Door; operator cycle

controls **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 22 1 4 22 **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** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$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.

H Duct Rear Seat to Battery Access Door Seal

340 030601-N05020-17

H Duct Rear Seat to Battery Access Door Small

Seal 50 030601-N05020-18 

### 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** **c k** **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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.07**

**$0.01**

**$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**

**$0.34 $0.17**  **$0.80 $0.00**  **$0.05 $0.04**  **$0.01 $0.10** 

**$0.90 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** **c k** **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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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!** 

-

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

-

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

-

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

-



## Purchase Part - High Impact Item (Full Cost Mapping)

Duct Rr Seat Batt Acs Dr: Foam Seal-340 &

Foam Seal-50 030601-N05020-15 **#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!** 

-

**120 30.00**  1.00

**#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!** 

-

H Duct Rear Seat Batt Access Door 030601-N05020-16



## 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!** 

-

**655 5.50**  0.25

**#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!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#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: 11 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.

H Duct Rear Seat to Battery Access Door Seal

340 030601-N05020-17

H Duct Rear Seat to Battery Access Door Small

Seal 50 030601-N05020-18**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

### 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: **T1 Moderate Assembly Complexity**


## 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: H Insulation Rear Seat Pan with Clips**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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**

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** 

### 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)**

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 Insulation Rr Seat Pan: Push Clips 030601-N05020-19 **1** Assemble Push Clips to

Insulation panel sheet T2/T3 Mech. Assembly, MSMC Not Applicable General Assembly Mech Assembly, LC, Base **150 2**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.51**  **$0.20 $0.71**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.10**  **$0.81 $0.81**  **$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 2**  **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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Insulation Rear Seat Pan with Clips**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

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 H Push Clips, Insulation, Rear Seat Pan 030601-N05020-20 **4** Mold T2/T3 Inject. Mold, MSMC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1575 0.25**  **1 1**  0.003 **$1.74 $41.48**  **$16.39 $16.39**  **$0.01 $0.01**  **$0.01 $0.02**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.00**  **$0.03 $0.10**  **$0.02**



### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 H Insulation, Rear Seat Pan 030601-N05020-21 **1** Waterjet cut insulator T2/T3 CNC Milling, SSLC Not Applicable CNC Operator CNC Machining, LC **240 1**  **1 1**  0.000 **$0.00 $36.98**  **$30.38 $30.38**  **$0.00 $0.15**  **$0.13 $0.28**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.31 $0.31**  **$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**



### 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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Insulation Rear Seat Pan with Clips**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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)**

1 H Insulation, Rear Seat Pan, Material 030601-N05020-22 **1** S **$0.00** $2.21 **$0.00 $2.21**  **$2.21**

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**

10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 **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.

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**

**$2.23**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total**

**Mark-up $3.43** 

**T1 or OEM Total Manufacturing Cost: $2.23**  **$0.69 $0.37**  **$3.29 $0.00**  **$0.07 $0.06**  **$0.01 $0.14**  **$3.43**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.02 $0.22**  **$0.21 $0.09**  **$0.53**

**Base Cost Impact to Vehicle: $2.23**  **$0.69 $0.37**  **$3.29 $0.02**  **$0.29 $0.27**  **$0.09 $0.67**  **$3.97 $0**  **$0 3**  **1**



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**Base Cost Impact to Vehicle: $2.23**  **$0.69 $0.37**  **$3.29 $0.02**  **$0.29 $0.27**  **$0.09 $0.67**  **$3.97 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $3.97** 



### Reference Packaging Database for Additonal Infromation
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: **T1 Moderate Assembly Complexity**


## 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: H Insulation Rear Seat Pan with Clips**  

## Part Number: **030601-N05020-00** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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 Returnables 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** **c k** **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** 

**$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)

Insulation Rr Seat Pan: Push Clips 030601-N05020-19 **$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** 

**$0.51 $0.20**  **$0.71 $0.00**  **$0.05 $0.04**  **$0.01 $0.10**  Assemble Push Pins (2x & 2x) to Insulation Rear Seat Pan by hand **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 48 1 1 48 **1.0 2.0** 

**$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 2.0**  **#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** 

**$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** **c k** **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** 

H Push Clips, Insulation, Rear Seat Pan 030601-N05020-20



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

H Insulation, Rear Seat Pan 030601-N05020-21 **$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** 

**$0.03 $0.04**  **$0.09 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  55-150 Ton Injection Molding w/ 14 cavity mold for Push Clip, Insulation; operator cycle controls **5 2**  **10 100**  **47 4700**  **383 9.40**  **85% 451**  **7.99** 32 1 14 32 **1.0 1.0** 

**$0.15 $0.13**  **$0.28 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  CNC Waterjet cutting machine create outline of Insulation, Rear Seat Pan, operator cycle & load / unload **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 15 1 1 15 **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** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$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.

H Insulation, Rear Seat Pan, Material 030601-N05020-22 

### 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** **c k** **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**

**$2.21**

**$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**

**$0.69 $0.37**  **$3.29 $0.00**  **$0.07 $0.06**  **$0.01 $0.14** 

**$3.43 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** **c k** **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!** 

-

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

-

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

-

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

-



## Purchase Part - High Impact Item (Full Cost Mapping)

Insulation Rr Seat Pan: Push Clips 030601-N05020-19 **#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!** 

-

**150 24.00**  2.00

**#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!** 

-

H Push Clips, Insulation, Rear Seat Pan 030601-N05020-20



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

H Insulation, Rear Seat Pan 030601-N05020-21 **#DIV/0! #DIV/0!** 

-

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

-

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

-

**1575 2.29**  0.25

**240 15.00**  1.00

**#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!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#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: 11 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.

H Insulation, Rear Seat Pan, Material 030601-N05020-22**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

# 14 **3 H Sound & Heat Control SubSy**  **stem Body QTY**  **$$$**

o **H Duct & Shield Rear Seat to Battery Asm 1** 

o A **H Duct Rear Seat to Battery - Molded 1** 

o H Duct Rear Seat to Battery Molded Foam Seal 480 1

o H Duct Rear Seat to Battery Molded Foam Seal 630 1

o H Push Pin Duct Rear Seat to Battery Molded Foam Seal 4

o H Duct Rear Seat to Battery Straight Foam Seal 900 1

o H Duct Rear Seat to Battery Access Door Small Seal 50 1

o H Nut Rear Seat to Battery Duct 4

o B **H Duct Rear Seat to Battery Access Door Asm 1** 

o **H Duct Rear Seat to Battery Access Door - Molded 1** 

o H Duct Rear Seat to Battery Access Door Seal 340 1

o H Duct Rear Seat to Battery Access Door Small Seal 50 1

o H Label, Duct Rear Seat to Battery Access Door 1

o C **H Insulation Rear Seat Pan with Clips 1** 

o **H Insulation Rear Seat Pan 1** 

o **H Push Clips, Insulation, Rear Seat Pan 2** 

o **H Push Clips, Insulation, Rear Seat Pan 2** 

# 25 0

# Comments

**PMAP**

**PMAP**

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

**PMAP**

**PMAP**

Commodity

Commodity

Commodity

**PMAP**

**PMAP**

**PMAP**

**PMAP**

# Indented Bill of Materials

**H Sound and Heat Control Subsy stem (Body**  **)**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total)** 

# 0 **H Duct Rear Seat to Battery H Duct Rear Seat to**  

# 1 **$0.48 2.0899 lb**  **#**
**Battery**

**1 H Duct Rear Seat to Battery**  **- H Duct Rear Seat to**  **1 Poly**  **propy lene**  **$0.00 1.9850 lb**  **#**

**Molded Battery**  **- Molded**

**2** H Duct Rear Seat to Battery - H Duct Rear Seat to **1 $0.00**  **1.9850 lb #** 

Material Battery - Material

1 H Foam Seal, Duct, 480mm (18.9") H Foam Seal, Duct 1 Commodity Pricing $0.09 0.0238 lb #

Rear Seat to Battery

1 H Foam Seal, Duct, 630mm (24.8") H Foam Seal, Duct 1 Commodity Pricing $0.12 0.0312 lb #

Rear Seat to Battery

1 H Push Pin Duct Rear Seat to H Push Pin - Duct 4 Commodity Pricing $0.02 0.0013 lb #

Battery Molded Foam S Rear Seat to Battery

Molded Foa

1 H Foam Seal, Duct, 900mm (35.4") H Foam Seal, Duct 1 Commodity Pricing $0.18 0.0445 lb #

Rear Seat to Battery

1 H Foam Seal, Duct Access, 50mm H Foam Seal, Duct 1 Commodity Pricing $0.01 0.0002 lb #

(1.97") Access Door, Small

0 H Nut Rear Seat to Battery Duct H Nut Rear Seat to 4 Commodity Pricing $0.02 0.0075 lb ##

Battery Duct

**0 H Duct Rear Seat to Battery**  **H Duct Rear Seat to 1**  **Poly propy**  **lene $0.28**  **0.2341 lb ##** 

**Ac cess Door**  **Battery A**  **ccess**

**Door**

**1 H Duct Rear Seat to Battery**  **H Duct Rear Seat to 1**  **Poly propy**  **lene $0.21**  **0.2170 lb #** 

**Ac cess Door - Molded**  **Battery A**  **ccess**

**Door - Molded**

**2** H Duct Rear Seat to Battery Access H Duct Rear Seat to **1** Polypropylene **$0.21 0.2170 lb**  **#**

Door - Material Battery Access Door

- Material

1 H Foam Seal, Duct, 340mm (13.4") H Foam Seal, Duct 1 Commodity Pricing $0.07 0.0169 lb #

Rear Seat to Battery

1 H Foam Seal, Duct Access, 50mm H Foam Seal, Duct 1 Commodity Pricing $0.01 0.0002 lb #

(1.97") Access Door, Small

0 H Label, Barcode, Duct Access H Label, Barcode, 1 Commodity Pricing $0.10 0.0004 lb ##

Panel Duct Access Panel

**0 H Insulation Rear Seat Pan with**  **H Insulation Rear 1**  **$2.23 0.2630 lb**  **##**

**Clips Seat Pan with Clips** 



# Design Profit

®

# Page 1 of 2

Copyright 2010 © Design Profit, Inc.

# H Sound and Heat Control Subsy **stem (Body )** 

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total)**

**H Insulation, Rear Seat Pan H Insulation, Rear**  **Mixed Poly , Film &**  

# ### **0.2560 lb #** 

**Seat Pan Foil** 

**2** H Insulation, Rear Seat Pan, H Insulation, Rear **1** Commodity Pricing **$2.21 0.2560 lb**  **#**

Material Seat Pan, Material

**1 H Push Clips, Insulation, Rear**  **H Push Clips, 2**  **PA 66**  **$0.01 0.0018 lb**  **#**

**Seat Pan Insulation, Rear** 

**Seat Pan**

**2** H Push Clips, Insulation, Rear Seat H Push Clips, **1** PA66 **$0.01 0.0000 lb**  **#**

Pan, Material Insulation, Rear Seat

Pan, Material

**1 H Push Clips, Insulation, Rear**  **H Push Clips, 2**  **PA 66**  **$0.01 0.0018 lb**  **#**

**Seat Pan Insulation, Rear** 

**Seat Pan**

**2** H Push Clips, Insulation, Rear Seat H Push Clips, **1** PA66 **$0.01 0.0000 lb**  **#**

Pan, Material Insulation, Rear Seat

Pan, Material 

# Assembly Totals 

# Report Totals **Preassembled Totals**

**An aly**  **zed Subs:** # 

# Piece Cost (Total): **Analyzed Subs:** 0

**Unanaly zed Subs:**  0 

# Unanalyzed Subs: 0 

# Weight (Total): 2.6174 lb

**Parts:** # 

# Parts: 0

**Fasteners:** 8 

# Fasteners: 0

**Parts+Unanaly**

**zed:** # 

# Parts+Unanalyzed: 0



# Design Profit

®

# Page 2 of 2

Copyright 2010 © Design Profit, Inc.

# Weight (Total)



# 2.0899 lb

**1.9850 lb**

**1.9850 lb**

0.0238 lb

0.0312 lb

0.0052 lb

0.0445 lb

0.0002 lb

0.0300 lb



# 0.2341 lb

**0.2170 lb**

**0.2170 lb**

0.0169 lb

0.0002 lb

0.0004 lb

**0.2630 lb**

# Weight (Total)

**0.2560 lb**

**0.2560 lb**

**0.0035 lb**

**0.0000 lb**

**0.0035 lb**

**0.0000 lb**

# Assembly Report

**H Sound and Heat Control Subsy stem (Body**  **)**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

$83.31 Tool H Sound and Heat First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Control
Subsystem (Body)

- - - Interior under seat

- - - - - - $90.59 Subassembly H Sound and Heat H Duct Rear Seat to Battery H Duct Rear Seat 9.0000 sec 9.0000 sec

- $0.21 1

Control to Battery
Subsystem (Body)

$90.59 Tool H Duct Rear Seat First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

to Battery

$90.59 P.-P. Part H Duct Rear Seat H Duct Rear Seat to Battery - H Duct Rear Seat 3.0000 sec 3.0000 sec $0.00 $0.08 1

to Battery Molded to Battery -

Molded

- - - "Injection Molding, Medium-Large

- - - - - -
Size and/or Moder

$90.59 Tool H Duct Rear Seat Inj Molding Machine 800-1500 0.0000 sec 0.0000 sec $0.00 $0.00 1

to Battery - Ton

Molded

$90.59 Part H Duct Rear Seat H Duct Rear Seat to Battery - H Duct Rear Seat 0.0000 sec **14.0020 sec** $0.00 $0.35 1 

# H Duct Rear Seat H Duct Rear Seat to Battery - H Duct Rear Seat 0.0000 sec **14.0020 sec**

to Battery - Material to Battery -

Molded Material

- - - Raw Material Req 2.117 lbs from

- - **-** - - -
Cost Sheet

- - - 2 Cavity Mold

- - **-** - - -

- - - Box Size 38.5"x8"x5"

- - **-** - - - $90.59 Part H Duct Rear Seat H Foam Seal, Duct, 480mm H Foam Seal, 9.0000 sec **9.0000 sec** $0.09 $0.23 1

to Battery (18.9") Duct Rear Seat to

Battery

$90.59 Operation H Duct Rear Seat Remove Adhesive Backing 5.6700 sec **5.6700 sec** $0.00 $0.14 1

to Battery

$90.59 Fastening H Duct Rear Seat Apply Adhesive Seal 4.7250 sec **4.7250 sec** $0.00 $0.12 1

to Battery

$90.59 Part H Duct Rear Seat H Foam Seal, Duct, 630mm H Foam Seal, 9.0000 sec **9.0000 sec** $0.12 $0.23 1

to Battery (24.8") Duct Rear Seat to

Battery

$90.59 Operation H Duct Rear Seat Remove Adhesive Backing 7.4400 sec **7.4400 sec** $0.00 $0.19 1

to Battery



# Design Profit ®

# Page 1 of 6

Copyright 2010 © Design Profit, Inc.

# H Sound and Heat Control Subsy **stem (Body )** 

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

$90.59 Fastening H Duct Rear Seat Apply Adhesive Seal 6.2000 sec **6.2000 sec** $0.00 $0.16 1

to Battery

$90.59 Part H Duct Rear Seat H Push Pin Duct Rear Seat to H Push Pin - Duct 5.0000 sec **5.0000 sec** $0.02 $0.13 4

to Battery Battery Molded Foam S Rear Seat to

Battery Molded

Foa

$90.59 Fastening H Duct Rear Seat Push In Place 2.0000 sec **2.0000 sec** $0.00 $0.05 4

to Battery

$90.59 Operation H Duct Rear Seat CDI 1.0000 sec **1.0000 sec** $0.00 $0.03 2

to Battery

$90.59 Operation H Duct Rear Seat 18" Move 2.0000 sec **2.0000 sec** $0.00 $0.05 2

to Battery

$90.59 Part H Duct Rear Seat H Foam Seal, Duct, 900mm H Foam Seal, 9.0000 sec **9.0000 sec** $0.18 $0.23 1

to Battery (35.4") Duct Rear Seat to

Battery

$90.59 Operation H Duct Rear Seat Remove Adhesive Backing 10.6200 sec **10.6200 sec** $0.00 $0.27 1

to Battery

$90.59 Fastening H Duct Rear Seat Apply Adhesive Seal 8.8500 sec **8.8500 sec** $0.00 $0.22 1

to Battery

$90.59 Part H Duct Rear Seat H Foam Seal, Duct Access, H Foam Seal, 9.0000 sec **9.0000 sec** $0.01 $0.23 1

to Battery 50mm(1.97") Duct Access Door,

Small



# $90.59 Operation H Duct Rear Seat Remove Adhesive Backing 0.5910 sec **0.5910 sec** $0.00 $0.01 1

to Battery

$90.59 Fastening H Duct Rear Seat Apply Adhesive Seal 0.4925 sec **0.4925 sec** $0.00 $0.01 1

to Battery

$83.31 Part H Sound and Heat H Nut Rear Seat to Battery Duct H Nut Rear Seat 7.0000 sec **7.0000 sec** $0.02 $0.16 4

Control to Battery Duct
Subsystem (Body)

$83.31 Tool H Sound and Heat Power Tool 4.0000 sec **4.0000 sec** $0.00 $0.09 1

Control
Subsystem (Body)

$83.31 Fastening H Sound and Heat Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.09 2

Control
Subsystem (Body)

$83.31 Operation H Sound and Heat 18" Move 2.0000 sec **2.0000 sec** $0.00 $0.05 1

Control
Subsystem (Body)

$83.31 Fastening H Sound and Heat Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.09 2

Control
Subsystem (Body)



# Design Profit ®

# Page 2 of 6

Copyright 2010 © Design Profit, Inc.

# H Sound and Heat Control Subsy **stem (Body )** 

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - High Voltage cables trapped in

- - **-** - - -

duct

$83.31 Fastening H Sound and Heat Press Together 3.0000 sec **3.0000 sec** $0.00 $0.07 1

Control
Subsystem (Body)

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $28.80 Subassembly H Sound and Heat H Duct Rear Seat to Battery H Duct Rear Seat 4.0000 sec **4.0000 sec**

- $0.09 1

Control Access Door to Battery Access
Subsystem (Body) Door

$28.80 Tool H Duct Rear Seat First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1

to Battery Access

Door

$28.80 P.-P. Part H Duct Rear Seat H Duct Rear Seat to Battery H Duct Rear Seat 3.0000 sec **3.0000 sec**

- $0.02 1

to Battery Access Access Door - Molded to Battery Access

Door Door - Molded

- - - "Injection Molding, Medium Size

- - **-** - - -
and/or Moderate Co

$28.80 Tool H Duct Rear Seat Injection Molding Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1

to Battery Access 200-400 Ton

Door - Molded

$28.80 Part H Duct Rear Seat H Duct Rear Seat to Battery H Duct Rear Seat 0.0000 sec **5.5960 sec** $0.21 $0.04 1 

# H Duct Rear Seat H Duct Rear Seat to Battery H Duct Rear Seat 0.0000 sec **5.5960 sec**

to Battery Access Access Door - Material to Battery Access

Door - Molded Door - Material

- - - Raw Material Req 0.248 lbs from

- - **-** - - -
Cost Sheet

- - - 4 Cavity Mold

- - **-** - - -

- - - Box Size 12.5"x4"x1.5"

- - **-** - - - $28.80 Part H Duct Rear Seat H Foam Seal, Duct, 340mm H Foam Seal, 9.0000 sec **9.0000 sec** $0.07 $0.07 1

to Battery Access (13.4") Duct Rear Seat to

Door Battery

$28.80 Operation H Duct Rear Seat Remove Adhesive Backing 4.0200 sec **4.0200 sec** $0.00 $0.03 1

to Battery Access

Door

$28.80 Fastening H Duct Rear Seat Apply Adhesive Seal 3.3500 sec **3.3500 sec** $0.00 $0.03 1

to Battery Access

Door

$28.80 Part H Duct Rear Seat H Foam Seal, Duct Access, H Foam Seal, 9.0000 sec **9.0000 sec** $0.01 $0.07 1

to Battery Access 50mm(1.97") Duct Access Door,

Door Small



# Design Profit ®

# Page 3 of 6

Copyright 2010 © Design Profit, Inc.

# H Sound and Heat Control Subsy **stem (Body )** 

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

$28.80 Operation H Duct Rear Seat Remove Adhesive Backing 0.5910 sec **0.5910 sec** $0.00 $0.00 1

to Battery Access

Door

$28.80 Fastening H Duct Rear Seat Apply Adhesive Seal 0.4925 sec **0.4925 sec** $0.00 $0.00 1

to Battery Access

Door

$83.31 Fastening H Sound and Heat Snap Together 1.0000 sec **1.0000 sec** $0.00 $0.02 2

Control
Subsystem (Body)

$83.31 Part H Sound and Heat H Label, Barcode, Duct Access H Label, Barcode, 9.0000 sec **9.0000 sec** $0.10 $0.21 1

Control Panel Duct Access
Subsystem (Body) Panel

$83.31 Fastening H Sound and Heat Apply Label 3.0000 sec **3.0000 sec** $0.00 $0.07 1

Control
Subsystem (Body)

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $35.51 Subassembly H Sound and Heat H Insulation Rear Seat Pan with H Insulation Rear 9.0000 sec **9.0000 sec**

- $0.21 1

Control Clips Seat Pan with
Subsystem (Body) Clips



# $35.51 Tool H Insulation Rear First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1

Seat Pan with
Clips

$44.85 P.-P. Part H Insulation Rear H Insulation, Rear Seat Pan H Insulation, Rear 6.0000 sec **6.0000 sec**

- $0.06 1

Seat Pan with Seat Pan
Clips

$44.85 Tool H Insulation, Rear Wa terjet 0.0000 sec **0.0000 sec** $0.00 $0.00 1

Seat Pan

$44.85 Part H Insulation, Rear H Insulation, Rear Seat Pan, H Insulation, Rear 0.0000 sec **0.0000 sec** $2.21 $0.00 1

Seat Pan Material Seat Pan, Material

$44.85 Fastening H Insulation, Rear Wa terjet, Rubber/Foam < 1" 15.2400 sec **15.2400 sec** $0.00 $0.19 1

Seat Pan

$16.39 P.-P. Part H Insulation Rear H Push Clips, Insulation, Rear H Push Clips, 8.0000 sec **8.0000 sec**

- $0.08 2

Seat Pan with Seat Pan Insulation, Rear
Clips Seat Pan

$16.39 Tool H Push Clips, Injection Molding Machine 55-150 0.0000 sec **0.0000 sec** $0.00 $0.00 2

Insulation, Rear ton

Seat Pan



# Design Profit ®

# Page 4 of 6

Copyright 2010 © Design Profit, Inc.

# H Sound and Heat Control Subsy **stem (Body )** 

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

$16.39 Part H Push Clips, H Push Clips, Insulation, Rear H Push Clips, 0.0000 sec **2.3290 sec** $0.01 $0.01 2

Insulation, Rear Seat Pan, Material Insulation, Rear

Seat Pan Seat Pan, Material

- - - Raw Material Req 0.003 lbs from

- - **-** - - -
Cost Sheet

- - - 14 Cavity Mold

- - **-** - - -

- - - Box Size 16mm L x 16mm W x

- - **-** - - -

16mm H

$35.51 Fastening H Insulation Rear Push In Place 2.0000 sec **2.0000 sec** $0.00 $0.02 2

Seat Pan with
Clips

$35.51 Operation H Insulation Rear 18" Move 2.0000 sec **2.0000 sec** $0.00 $0.02 1

Seat Pan with
Clips

$16.39 P.-P. Part H Insulation Rear H Push Clips, Insulation, Rear H Push Clips, 8.0000 sec **8.0000 sec**

- $0.08 2

Seat Pan with Seat Pan Insulation, Rear
Clips Seat Pan

$16.39 Tool H Push Clips, Injection Molding Machine 55-150 0.0000 sec **0.0000 sec** $0.00 $0.00 2

Insulation, Rear ton

Seat Pan

$16.39 Part H Push Clips, H Push Clips, Insulation, Rear H Push Clips, 0.0000 sec **2.3290 sec** $0.01 $0.01 2

Insulation, Rear Seat Pan, Material Insulation, Rear



# Seat Pan Seat Pan, Material

- - - Raw Material Req 0.003 lbs from

- - **-** - - -
Cost Sheet

- - - 14 Cavity Mold

- - **-** - - -

- - - Box Size 16mm L x 16mm W x

- - **-** - - -
16mm H

$35.51 Fastening H Insulation Rear Push In Place 2.0000 sec **2.0000 sec** $0.00 $0.02 2

Seat Pan with
Clips

$83.31 Fastening H Sound and Heat Press in Xmass Clip 3.0000 sec **3.0000 sec** $0.00 $0.07 2

Control
Subsystem (Body)

$83.31 Operation H Sound and Heat 18" Move 2.0000 sec **2.0000 sec** $0.00 $0.05 1

Control
Subsystem (Body)

$83.31 Fastening H Sound and Heat Press in Xmass Clip 3.0000 sec **3.0000 sec** $0.00 $0.07 2

Control
Subsystem (Body)



# Design Profit ®

# Page 5 of 6

Copyright 2010 © Design Profit, Inc.

# H Sound and Heat Control Subsy **stem (Body )** 

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** 

# Report Totals **Count:** 82

**84**



# Design Profit ®

Page 6 of 6

# Copyright 2010 © Design Profit, Inc.

# Piece Co

**(Total)**

$0.00

-

-

$0.00

$0.00

-

$0.00

$0.00



# -

-

- $0.09

$0.00

$0.00

$0.12

$0.00

# Piece Co

**(Total)**

$0.00

$0.08

$0.00

$0.00

$0.00

$0.18

$0.00

$0.00

$0.01



# $0.00

$0.00

$0.09

$0.00

$0.00

$0.00

$0.00

# Piece Co

**(Total)**

-

$0.00

-

-

-

$0.00

-

-

$0.00

$0.21



# -

-

- $0.07

$0.00

$0.00

$0.01

# Piece Co

**(Total)**

$0.00

$0.00

$0.00

$0.10

$0.00

-

-

-

-

-



# $0.00

-

$0.00

$2.21

$0.00

-

$0.00

# Piece Co

**(Total)**

$0.01

-

-

-

$0.00

$0.00

-

$0.00

$0.01



# -

-

-

$0.00

$0.00

$0.00

$0.00

# Piece Co

**(Total)**

**$3.19**

### 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: **T1 Moderate Assembly Complexity**


## 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: H Seating Subsystem**  

## Part Number: **020200-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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**

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** 

### 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**  **Parallel 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)**

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**

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**



### 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: **T1 Moderate Assembly Complexity**


## 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: H Seating Subsystem**  

## Part Number: **020200-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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**  **Parallel 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)**

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**



### 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** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub



### 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: **T1 Moderate Assembly Complexity**


## 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: H Seating Subsystem**  

## Part Number: **020200-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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**  **Parallel 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)**

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**

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** 

### "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.

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:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**Base Cost Impact to Vehicle: $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.00**  **3 1** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**Net Cost Impact to Vehicle: $0.00** 

**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** **)** 

### PACKAGING CALCULATIONS:
Packaging Type:

Part Size:
Parts/Layer:
Number of Layers: **Reference Packaging Database for Additonal Infromation**
Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)

Assume Plastic Returnables 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



### 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: **T1 Moderate Assembly Complexity**


## 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: H Seating Subsystem**  

## Part Number: **020200-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**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**  **Parallel 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)**

**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 Cost Total: **$0.000** 

### 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 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** **c k** **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** 

**$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**  **#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** 

**$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** **c k** **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** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$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**



### 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.



### 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** **c k** **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**

**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** **c k** **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!** 

-

**#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!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#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: 11 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

### 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