### Page:1 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

# 021300 OE Transmission A **ssembly Line - Final** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  **- $**  **58.49**

**$ 44.17** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

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

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

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

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

**- $**  **58.49**

**$ 44.17** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### -

**$ -** 

**$ -** 

**$ -** 

**$ 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 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

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

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

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

# 05 **Cy linder Blocks** 
A1 **01**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** B1 **02**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** C1 **03**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
-

$
-

$ #REF! #REF! #REF! **#REF!** 

### 2 #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$** 

### #REF! #REF! #REF! **#REF!** E1 **65**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** F1 **66**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATION
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

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

# BASE **TECHNO LOGY**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem



### G1 **67**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$**

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

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

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

H1 **70**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** I1 **75**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** J1 **80**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** K1 **85**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** L1 **90**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** M1 **99**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** N1 **00**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** $ $ **$** $ $ $ $ **$** $ **$** $ $ $ $ $ **$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$ SU**  **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$** 

### #REF! #REF! #REF! **#REF!**

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

# 05 **Cy linder Blocks** 
A1 **01**
- $ 58.49

$ 44.17

$ **102.66**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **102.66**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### B1 **02**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### C1 **03**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
-

$
-

$ #REF! #REF! #REF! **#REF!** 

### E1 **65**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### F1 **66 -**  **$ -**  **$ -**  **$ -**  **$ System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# TECHNO **LOGY PACKAG**  **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**ItemSubsystemSub-Subsystem 

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

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

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



### F1 **66**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:5 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

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

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

G1 **67**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### H1 **70**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### I1 **75**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### J1 **80**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### K1 **85**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### L1 **90**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** M1 **99**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** $ $ **$** $ $ $ $ **$** $ **$** $ $ $ $ $ **$** 

### N1 **00**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### SU **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$** 

### #REF! #REF! #REF! **#REF!**

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:6 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# 021300 OE Transmission A **ssembly Line - Final** 
1 **00** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a**



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem


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

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 58.49** 

**$ 44.17** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 102.66** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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



### 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:7 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem


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

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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



### - **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### -

**$ 58.49** 

**$ 44.17** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 102.66** 

**$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:8 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem


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

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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



# 05 **Cy linder Blocks** 
A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 2 

# BASE **TECHNO LOGY** ItemSubsystemSub-Subsystem


### End Item

Scrap SG&A Profit ED&T-R&D

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
-

$
-

$ 

### #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$ Tooling**  **(x1000)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

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

# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Investment (X1000)** 



### G1 **67** 2 -

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:9 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99** 2 N1 **00** End Item

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

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$ 

### N1 **00** 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks** 
A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** F1 **66** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem 

### -

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$**

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

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$ #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

**- $**  **- $**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 



### F1 **66**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:10 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90** M1 **99** End Item

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

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$ 

### M1 **99** N1 **00**

**SU BS**  **YS** - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$


### #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:11 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# 021300 OE Transmission A **ssembly Line - Final** 
1 **00** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a**



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### - **$**

**- $** 

**- $** 

**- $** 

**- $**  **Investment(X1 000)** 



### 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a -** 

**$**

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $**  

### 0 **n/a -** 

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:12 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### 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:13 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Investment(X1 **000)**



# 05 **Cy linder Blocks** 
A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 2 

# BASE **TECHNO LOGY** ItemSubsystemSub-Subsystem



### G1 **67** 2

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:14 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99** 2 N1 **00 Investment(X1** 

**000)**



### 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks** 
A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** F1 **66** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem



### F1 **66**

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:15 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90** M1 **99 Investment(X1** 

**000)**



### N1 **00**

**SU BS**  **YS**

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: 8/30/2012 DRAFT

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



### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

# 021300 OE Transmission A **ssembly Line - Final** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  **- $**  **58.49**

**$ 44.17** 

**$ 102.66** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 102.66** 

**$ -** 

**$** 

### A A OE Transmission Assembly Line - Final 02 # 00
- N0502
- 01 1 Full 1


### - $ 58.49

$ 44.17

$ **102.66**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **102.66**

**$ -** 

**$**



### 2 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**Sub-SubsystemAssembly 

### Name/Description Part Number 

# 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)** ItemSubsystemSubassemblyComponent 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) System**  **ED&T/R&D (x1000)**  

# NEW TECHNOLOGY PACKAGE QUOTE

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

2 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 3 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 4 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 5 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 6 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 7 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 8 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 9 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### B H Bolt Battery Terminal Bottom 14 03 80
- N0502
- 02 52 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 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: 8/30/2012 DRAFT

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

### Name/Description Part Number 

# 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)** ItemSubsystemSubassemblyComponent 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) System**  **ED&T/R&D (x1000)**  

# NEW TECHNOLOGY PACKAGE QUOTE

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

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

10 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 11 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 12 **tbd -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### - $ 58.49

$ 44.17

$ **102.66**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **102.66**

**$ -** 

**$**



### 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**  Complete Subsystem Quote (Yes/No) 

## YES

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: 8/30/2012 DRAFT

0 **n/a n/a**  

# 021300 OE Transmission A **ssembly Line - Final** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  A A OE Transmission Assembly Line - Final 02 # 00
- N0502
- 01 1 Full 1



### 2 **tbd**Sub-SubsystemAssembly 

### Name/Description Part Number



# 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)** ItemSubsystemSubassemblyComponentQTY/Subsystem 

### Notes 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS** 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 Vehicle, 4
- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### 2 **tbd**

3 **tbd**

4 **tbd**

5 **tbd**

6 **tbd**

7 **tbd**

8 **tbd**

9 **tbd -**  **$ -** 

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$** 

### 9 **tbd** B H Bolt Battery Terminal Bottom 14 03 80
- N0502
- 02 52 Full 1 **- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**



### 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: 8/30/2012 DRAFTSub-SubsystemAssembly 

### Name/Description Part Number 

# 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)** ItemSubsystemSubassemblyComponentQTY/Subsystem 

### Notes 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS** 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 Vehicle, 4
- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

10 **tbd**

11 **tbd**

12 **tbd 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**  Complete Subsystem Quote (Yes/No) 

## YES **- $**  **-**

**$**



### 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: 8/30/2012 DRAFT

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



### 0 **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

# 021300 OE Transmission A **ssembly Line - Final** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 2 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 3 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**Assembly 

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

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)** Sub-Subsystem 

### Part NumberSubassemblyComponent 

# 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 BASE TECHNOLOGY PACKAGE COST INFORMATION** QTY/Subsystem 

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

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

# Study Case#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 4 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 5 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 6 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 7 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 8 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 9 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 10 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 11 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 12 **tbd 0**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 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: 8/30/2012 DRAFT

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

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

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)** Sub-Subsystem 

### Part NumberSubassemblyComponent 

# 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 BASE TECHNOLOGY PACKAGE COST INFORMATION** QTY/Subsystem 

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

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

# Study Case#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### NOTES: 

## 1. Complete Subsystem Quote (Yes/No)
**= 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: 8/30/2012 DRAFT

0 

# 021300 OE Transmission A **ssembly Line - Final** 
1 **00 Assembly of High Voltage Traction Battery Subsystem** 

2 **tbd 0** 
3 **tbd 0** Assembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1)Sub-Subsystem 

### Part NumberSubassemblyComponent 

# 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**QTY/Subsystem 

### Notes 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

# Study Case#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### 4 **tbd 0** 

5 **tbd 0** 
6 **tbd 0** 

7 **tbd 0** 
8 **tbd 0** 

9 **tbd 0** 
10 **tbd 0** 

11 **tbd 0** 

12 **tbd 0**  **- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**



### 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: 8/30/2012 DRAFTAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1)Sub-Subsystem 

### Part NumberSubassemblyComponent 

# 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**QTY/Subsystem 

### Notes 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

# Study Case#: B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle) Class)

**NOTES:** 

## 1. Complete Subsystem Quote (Yes/No)
**= 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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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 1A VO Transmission Assembly Oper 5 140300-N0502-01-01 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00** 2 2A VO Transmission Assembly Oper 10 140300-N0502-01-02 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
3 3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03 **1** Washer OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
4 4A VO Transmission Assembly Oper 15 140300-N0502-01-04 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
5 5A VO Transmission Assembly Oper 20 140300-N0502-01-05 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

6 6A VO Transmission Assembly Oper 30 140300-N0502-01-06 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
7 7A VO Transmission Assembly Oper 40 140300-N0502-01-07 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
8 8A VO Transmission Assembly Oper 50 140300-N0502-01-08 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
9 9A VO Transmission Assembly Oper 60 140300-N0502-01-09 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
10 10A VO Transmission Assembly Oper 70 140300-N0502-01-10 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
11 11A VO Transmission Assembly Oper 80 140300-N0502-01-11 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
12 12A VO Transmission Assembly Oper 90 140300-N0502-01-12 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
13 13A VO Transmission Assembly Oper 100 140300-N0502-01-13 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
14 14A VO Transmission Assembly Oper 110 140300-N0502-01-14 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
15 15A VO Transmission Assembly Oper 120 140300-N0502-01-15 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
16 16A VO Transmission Assembly Oper 130 140300-N0502-01-16 **1** Functional Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
17 17A VO Transmission Assembly Oper 140 140300-N0502-01-17 **1** Functional Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
18 18A VO Transmission Assembly Oper 150 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
19 18A VO Transmission Assembly Oper 160 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
20 20A VO Transmission Assembly Oper 170 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00** 

### OEM, LMC 21 21A VO Transmission Assembly Oper 180 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
22 22A VO Transmission Assembly Oper 190 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
23 23A VO Transmission Assembly Oper 200 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
24 24A VO Transmission Assembly Oper 210 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
25 25A VO Transmission Assembly Oper 220 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

26 26A VO Transmission Assembly Oper 230 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
27 27A VO Transmission Assembly Oper 240 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
28 28A VO Transmission Assembly Oper 250 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
29 29A VO Transmission Assembly Oper 260 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
30 30A VO Transmission Assembly Oper 270 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
31 31A VO Transmission Assembly Oper 280 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00** 

### Assembly, OEM, MC 32 32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 **1** Gage OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
33 33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18 **1** RTV OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
34 34A VO Transmission Assembly Oper 290 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
35 35A VO Transmission Assembly Oper 300 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $1.30**  **$0.17 $1.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.47 $1.47**  **$0.00**
36 36A VO Transmission Assembly Oper 310 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
37 37A VO Transmission Assembly Oper 320 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
38 38A VO Transmission Assembly Oper 330 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
39 39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 **1** Gage OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00**
40 40 VO Transmission Assembly Oper 340 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
41 41A VO Transmission Assembly Oper 350 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
42 42A VO Transmission Assembly Oper 360 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
43 43A VO Transmission Assembly Oper 370 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
44 44A VO Transmission Assembly Oper 380 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
45 45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 **1** Press OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
46 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00** 46 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
47 47A VO Transmission Assembly Oper 400 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
48 48A VO Transmission Assembly Oper 410 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
49 49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 **1** Press OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
50 50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 **1** Press OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
51 51A VO Transmission Assembly Oper 420 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

52 52A VO Transmission Assembly Oper 430 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
53 53A VO Transmission Assembly Oper 440 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
54 54A VO Transmission Assembly Oper 450 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
55 55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 **1** Gage OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $0.65**  **$0.83 $1.48**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.48 $1.48**  **$0.00**
56 56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
57 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00** 57 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
58 58A VO Transmission Assembly Oper 460 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
59 59A VO Transmission Assembly Oper 470 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $1.30**  **$0.17 $1.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.47 $1.47**  **$0.00**
60 60A VO Transmission Assembly Oper 480 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
61 61A VO Transmission Assembly Oper 490 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
62 62A VO Transmission Assembly Oper 500 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00**
63 63A VO Transmission Assembly Oper 510 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
64 64A VO Transmission Assembly Oper 520 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
65 65A VO Transmission Assembly Oper 530 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
66 66A VO Transmission Assembly Oper 540 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.65**  **$0.33 $0.98**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.98 $0.98**  **$0.00**
67 67A VO Transmission Assembly Oper 550 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
68 68A VO Transmission Assembly Oper 560 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $1.30**  **$0.17 $1.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.47 $1.47**  **$0.00**
69 69A VO Transmission Assembly Oper 570 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
70 70A VO Transmission Assembly Oper 580 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $1.30**  **$0.17 $1.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.47 $1.47**  **$0.00**
71 71A VO Transmission Assembly Oper 590 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $1.30**  **$0.17 $1.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.47 $1.47**  **$0.00**
72 72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00** 72 72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00**
73 73A VO Transmission Assembly Oper 610 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
74 74A VO Transmission Assembly Oper 620 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
75 75A VO Transmission Assembly Oper 630 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
76 76A VO Transmission Assembly Oper 640 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
77 77A VO Transmission Assembly Oper 650 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$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: 4 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

78 78A VO Transmission Assembly Oper 660 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
79 79A VO Transmission Assembly Oper 670 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
80 80A VO Transmission Assembly Oper 680 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 4**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $2.60**  **$0.33 $2.93**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$2.93 $2.93**  **$0.00**
81 81A VO Transmission Assembly Oper 690 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
82 82A VO Transmission Assembly Oper 700 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
83 83A VO Transmission Assembly Oper 710 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00** 

### OEM, LMC 84 84A VO Transmission Assembly Oper 720 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
85 85A VO Transmission Assembly Oper 730 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
86 86A VO Transmission Assembly Oper 740 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
87 87A VO Transmission Assembly Oper 750 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
88 88A VO Transmission Assembly Oper 760 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
89 89A VO Transmission Assembly Oper 770 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
90 90A VO Transmission Assembly Oper 780 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
91 91A VO Transmission Assembly Oper 790 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
92 92A VO Transmission Assembly Oper 800 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
93 93A VO Transmission Assembly Oper 810 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $1.30**  **$0.17 $1.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.47 $1.47**  **$0.00**
94 94A VO Transmission Assembly Oper 820 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
95 95A VO Transmission Assembly Oper 830 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MHC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$75.00 $75.00**  **$0.00 $0.00**  **$0.50 $0.50**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.50 $0.50**  **$0.00**
96 96A VO Transmission Assembly Oper 840 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
97 97A VO Transmission Assembly Oper 850 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
98 98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00** 98 98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
99 99A VO Transmission Assembly Oper 870 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
100 100A VO Transmission Assembly Oper 880 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
101 101A VO Transmission Assembly Oper 890 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$0.00**
102 102A VO Transmission Assembly Oper 900 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
103 103A VO Transmission Assembly Oper 910 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$25.00 $25.00**  **$0.00 $0.65**  **$0.17 $0.82**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.82 $0.82**  **$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: 5 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

104 104A VO Transmission Assembly Oper 920 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
105 105A VO Transmission Assembly Oper 930 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
106 106A VO Transmission Assembly Test loop 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
107 107A VO Transmission Assembly Test 10 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 1**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $3.25**  **$4.17 $7.42**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$7.42 $7.42**  **$0.00**
108 108A VO Transmission Assembly Test 20 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 0**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $0.00**  **$4.17 $4.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$4.17 $4.17**  **$0.00**
109 109A VO Transmission Assembly Test 30 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 1**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $3.25**  **$4.17 $7.42**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$7.42 $7.42**  **$0.00** 

### OEM, HC 110 110A VO Transmission Assembly Test 40 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 0**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $0.00**  **$4.17 $4.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$4.17 $4.17**  **$0.00**
111 111A VO Transmission Assembly Test 50 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 1**  **1 1**  0.000 **$0.00 $97.48**  **$125.00 $125.00**  **$0.00 $3.25**  **$4.17 $7.42**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$7.42 $7.42**  **$0.00**
112 112A VO Transmission Assembly Oper 940 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
113 113A VO Transmission Assembly Oper 950 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
114 114A VO Transmission Assembly Oper 960 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
115 115A VO Transmission Assembly Oper 970 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
116 116A VO Transmission Assembly Oper 980 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.65**  **$0.10 $0.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.75 $0.75**  **$0.00**
117 117A VO Transmission Assembly Oper 990 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
118 118A VO Transmission Assembly Oper 1000 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
119 119A VO Transmission Assembly Oper 1010 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
120 120A VO Transmission Assembly Oper 1020 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
121 121A VO Transmission Assembly Oper 1030 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 2**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $1.30**  **$0.10 $1.40**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.40 $1.40**  **$0.00**
122 122A VO Transmission Assembly Oper 1040 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
123 123A VO Transmission Assembly Oper 1050 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$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 3**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**



### 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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

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** 

### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 **0 #####**  **0 1**  **1** 0.000 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #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 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #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**



### 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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 0**  **$0.00** $0.00 **$0.00 $0.00**  112 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 113 **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 Material**  **$0.00**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$102.66 T1 or OEM Total Manufacturing Cost:**  **$0.00 $58.49**  **$44.17 $102.66**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $102.66** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00% **(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 $58.49**  **$44.17 $102.66**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $102.66**  **$0 $0**  **Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $102.66** 

**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 **57** 1000 **6 56250** 
**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**  

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **3 1**  

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



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable 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. **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** 

### 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: 8 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: **OEM Assembly, Mark-up Covered by ICM** 

## 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: OE Transmission Assembly Line - Final**  

## Part Number: **021300-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**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**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**



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



### 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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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) 1A VO Transmission Assembly Oper 5 140300-N0502-01-01 2A VO Transmission Assembly Oper 10 140300-N0502-01-02
3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03
4A VO Transmission Assembly Oper 15 140300-N0502-01-04
5A VO Transmission Assembly Oper 20 140300-N0502-01-05



### 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 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper.5 Auto load case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 10 W assher automation **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. Off-Line Part washer **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 15 Loaad case to assembly pallet **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 20 Auto clamp case to pallet and rotate **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **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**

6A VO Transmission Assembly Oper 30 140300-N0502-01-06
7A VO Transmission Assembly Oper 40 140300-N0502-01-07
8A VO Transmission Assembly Oper 50 140300-N0502-01-08
9A VO Transmission Assembly Oper 60 140300-N0502-01-09
10A VO Transmission Assembly Oper 70 140300-N0502-01-10
11A VO Transmission Assembly Oper 80 140300-N0502-01-11
12A VO Transmission Assembly Oper 90 140300-N0502-01-12
13A VO Transmission Assembly Oper 100 140300-N0502-01-13
14A VO Transmission Assembly Oper 110 140300-N0502-01-14
15A VO Transmission Assembly Oper 120 140300-N0502-01-15
16A VO Transmission Assembly Oper 130 140300-N0502-01-16
17A VO Transmission Assembly Oper 140 140300-N0502-01-17
18A VO Transmission Assembly Oper 150 140300-N0502-01-18
18A VO Transmission Assembly Oper 160 140300-N0502-01-18
20A VO Transmission Assembly Oper 170 140300-N0502-01-18 **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 30 Press in traction motor bearing and park lever seal **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 40 Press dowels in case for cover and planetary housing, air assemble air inlet cover & r/d 1 bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 50 nstall park lever comb & bullet assembly into case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 60 Align rooster comb shaft holes & install pin **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  oper 70 Install 2 park lever springs and r/d spring bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 80 Rotate housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 90 Press to case 2 cover dowels & assemble 3 bearing shims to 3 beaing bores **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 100 Load & press 2 tapered bearing races **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 110 Load & press 1 tapered bearng race and 1 ball bearing race **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 120 Install bullet receiver sleeve, half round bullet locator, position parking pawl arm, parking pawl pivot pin and spring **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 130 position bullet reciever and r/d 2 screws **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 140 Install oil pump assembly, r/d 3 bolts, install short passage tube **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 150 Install ling oil passage tube, mounting bracket, r/d 2 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 160 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 170 Repair bay entrance / exit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 
21A VO Transmission Assembly Oper 180 140300-N0502-01-18
22A VO Transmission Assembly Oper 190 140300-N0502-01-18
23A VO Transmission Assembly Oper 200 140300-N0502-01-18
24A VO Transmission Assembly Oper 210 140300-N0502-01-18
25A VO Transmission Assembly Oper 220 140300-N0502-01-18 **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 180 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 190 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 200 Install planetary assembly, oil pump drive and planet housing cover **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 210 Start, r/d 7 planetary housing cover bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 220 Position generator spped sensor wire harness thru case opening, attach wire to sensor, install speed senor - generator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **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: 10 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

26A VO Transmission Assembly Oper 230 140300-N0502-01-18
27A VO Transmission Assembly Oper 240 140300-N0502-01-18
28A VO Transmission Assembly Oper 250 140300-N0502-01-18
29A VO Transmission Assembly Oper 260 140300-N0502-01-18
30A VO Transmission Assembly Oper 270 140300-N0502-01-18
31A VO Transmission Assembly Oper 280 140300-N0502-01-18 

### 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**

**$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 230 start & r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 240 Position 2 generator & motor isolators thru case opening and start, r/d 2 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 250 position motor speed sensor wire harness thru case and attach to sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 260 Install speed sensor (traction motor) and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 270 Install generator assembly, position speed sensor wire clip on bolt boss and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 280 Install traction motor assembly, position speed sensor wire clip on bolt boss and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 
32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18
34A VO Transmission Assembly Oper 290 140300-N0502-01-18
35A VO Transmission Assembly Oper 300 140300-N0502-01-18
36A VO Transmission Assembly Oper 310 140300-N0502-01-18
37A VO Transmission Assembly Oper 320 140300-N0502-01-18
38A VO Transmission Assembly Oper 330 140300-N0502-01-18
39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
40 VO Transmission Assembly Oper 340 140300-N0502-01-18
41A VO Transmission Assembly Oper 350 140300-N0502-01-18
42A VO Transmission Assembly Oper 360 140300-N0502-01-18
43A VO Transmission Assembly Oper 370 140300-N0502-01-18
44A VO Transmission Assembly Oper 380 140300-N0502-01-18
45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper off-line gage cover rail to generator and motor bearings pockets / bearings and select shim and install in case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper off-line RTV cover **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 290 pick and place cover over dowels to case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.30 $0.17**  **$1.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 300 Start and r/d to zero torquw 20 cover bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 310 Auto r/d 20 cover bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 320 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 330 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line gage end play and torque to turn **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 340 Repair bay entrance / exit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 350 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 360 Position traction speed sensor wire clip & r/d 1 bolts, position generator speed sensor wire clip & r/d 2 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 370 Install 6 terminal leads thru case and start, r/d 1 bolt per lead **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 380 Position motor and generator wires to terminal leads and start & r/d 1 bolts per wire **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-Line Press inner roller bearings into both ends of generator transfer shaft, and outer ball bearing to cover side generator transfer shaft and tapered bearing to case side **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 390 Align and press traction motor transfer shaft thru roller bearing in case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  46A VO Transmission Assembly Oper 390 140300-N0502-01-18
47A VO Transmission Assembly Oper 400 140300-N0502-01-18
48A VO Transmission Assembly Oper 410 140300-N0502-01-18
49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
51A VO Transmission Assembly Oper 420 140300-N0502-01-18 **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 390 Align and press traction motor transfer shaft thru roller bearing in case and OD spline into traction rotor shaft ID spline **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 400 Press transfer shaft over generator planetary shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 410 Align and assemble differential assembly into case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line press taper bearing on case side of output shaft, press outer gear set into transfer gear output shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line press taper bearing on cover side of output shaft, start & r/d 1 nut on output shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 420 Install output shaft assemmbly into case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **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: 11 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

52A VO Transmission Assembly Oper 430 140300-N0502-01-18
53A VO Transmission Assembly Oper 440 140300-N0502-01-18
54A VO Transmission Assembly Oper 450 140300-N0502-01-18
55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 

### 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**

**$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 430 Press roller bearing onto traction motor transfer shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 440 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 450 Measure height from case rail to taper bearing race on differential, output dhaft and both transfer shafts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.83**  **$1.48 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper off-line, load bell housing, measure cover rail to above mentioned bearing pocket depths and select shims and install in cover and load / press 3 races into cover **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line install oil diffuser and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line RTV gear side of bell housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
58A VO Transmission Assembly Oper 460 140300-N0502-01-18
59A VO Transmission Assembly Oper 470 140300-N0502-01-18
60A VO Transmission Assembly Oper 480 140300-N0502-01-18
61A VO Transmission Assembly Oper 490 140300-N0502-01-18
62A VO Transmission Assembly Oper 500 140300-N0502-01-18
63A VO Transmission Assembly Oper 510 140300-N0502-01-18
64A VO Transmission Assembly Oper 520 140300-N0502-01-18
65A VO Transmission Assembly Oper 530 140300-N0502-01-18
66A VO Transmission Assembly Oper 540 140300-N0502-01-18
67A VO Transmission Assembly Oper 550 140300-N0502-01-18
68A VO Transmission Assembly Oper 560 140300-N0502-01-18
69A VO Transmission Assembly Oper 570 140300-N0502-01-18
70A VO Transmission Assembly Oper 580 140300-N0502-01-18
71A VO Transmission Assembly Oper 590 140300-N0502-01-18
72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line RTV gear side of bell housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 460 Auto place bell housing over dowels on case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.30 $0.17**  **$1.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 470 Start and r/d to zero torque 21 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 480 Auto r/d 21 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 490 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 500 Torque to turn output shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 510 Repair bay entrance / exit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 520 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 530 rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.33**  **$0.98 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 540 install seal in output shaft bores on both side of case and install input shaft seal to bell housing side **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 550 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.30 $0.17**  **$1.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 560 Install oil cooler gasket, oil cooler cover and start, r/d 19 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 570 Install 2 dowels and electronic housing gasket **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.30 $0.17**  **$1.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 580 Position electronic housing over dowels 7 start 2 bolts, start, r/d to zero torque 10 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.30 $0.17**  **$1.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 590 Start and r/d to zero torque 20 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 600 Auto r/d 32 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  72A VO Transmission Assembly Oper 600 140300-N0502-01-18
73A VO Transmission Assembly Oper 610 140300-N0502-01-18
74A VO Transmission Assembly Oper 620 140300-N0502-01-18
75A VO Transmission Assembly Oper 630 140300-N0502-01-18
76A VO Transmission Assembly Oper 640 140300-N0502-01-18
77A VO Transmission Assembly Oper 650 140300-N0502-01-18 **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 600 Auto r/d 32 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  oper 610 Install 2 current sensor bars over terminal leads, start & r/d 2 bolts into each current sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 620 Install traction motor control unit & r/d 6 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 630 Install generator control unit & r/d 6 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 640 Install Denso control unit & r/d 4 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 650 Install 3 bus bars between traction control unit and current sensor bar & r/d 2 bolts each **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **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: 12 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

78A VO Transmission Assembly Oper 660 140300-N0502-01-18
79A VO Transmission Assembly Oper 670 140300-N0502-01-18
80A VO Transmission Assembly Oper 680 140300-N0502-01-18
81A VO Transmission Assembly Oper 690 140300-N0502-01-18
82A VO Transmission Assembly Oper 700 140300-N0502-01-18
83A VO Transmission Assembly Oper 710 140300-N0502-01-18 

### 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**

**$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 660 Install 3 bus bars between generator control unit and sensor bar & r/d 2 bolts each **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 670 Route all wires off control units before install cover then install wire harness into each control unit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$2.60 $0.33**  **$2.93 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line Main Control build up loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 690 Install main control start & r/d 6 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 700 Fasten 3 wire clips and insert 4 wire connectors to circuit board **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 710 Install short bar, start, r/d nut / bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 
84A VO Transmission Assembly Oper 720 140300-N0502-01-18
85A VO Transmission Assembly Oper 730 140300-N0502-01-18
86A VO Transmission Assembly Oper 740 140300-N0502-01-18
87A VO Transmission Assembly Oper 750 140300-N0502-01-18
88A VO Transmission Assembly Oper 760 140300-N0502-01-18
89A VO Transmission Assembly Oper 770 140300-N0502-01-18
90A VO Transmission Assembly Oper 780 140300-N0502-01-18
91A VO Transmission Assembly Oper 790 140300-N0502-01-18
92A VO Transmission Assembly Oper 800 140300-N0502-01-18
93A VO Transmission Assembly Oper 810 140300-N0502-01-18
94A VO Transmission Assembly Oper 820 140300-N0502-01-18
95A VO Transmission Assembly Oper 830 140300-N0502-01-18
96A VO Transmission Assembly Oper 840 140300-N0502-01-18
97A VO Transmission Assembly Oper 850 140300-N0502-01-18
98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 720 install medium bar, start, r/d nut / bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  oper 730 Install long bar, start, r/dnut /bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 740 Connect & r/d wires to lower black box **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 750 Install TACM connector to electronic housing, insert wire thru hole, start & r/d 3 bolts and terminate 2 wires to stud & r/d 2 nuts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 760 Install 2 TACM #2 connectors and r/d 1 bolt each **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 770 Install large harness guide, start & r/d 4 screws **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 780 Install 5 harness clips to harness guide, r/d ground stud **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 790 Ppsition 3 wire harness with 7 connectors, terminate / plug in 9 connectors includes 2 existing connectors **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 800 Install cork gasket to electronic housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.30 $0.17**  **$1.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 810 Position cover & tab assembly, start & r/d to zero torque 2 studs **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 820 Install & r/d to zero torque 18 bolts and 4 studs **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.50**  **$0.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 830 Auto r/d 22 fasteners **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 840 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 850 Install shift lever indicator, lever, locking clamp, r/d 2 bolts, 1 stud **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 860 Install & r/d 2 studs w/ nuts, 2 coolant outlets and 1 temp sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  98A VO Transmission Assembly Oper 860 140300-N0502-01-18
99A VO Transmission Assembly Oper 870 140300-N0502-01-18
100A VO Transmission Assembly Oper 880 140300-N0502-01-18
101A VO Transmission Assembly Oper 890 140300-N0502-01-18
102A VO Transmission Assembly Oper 900 140300-N0502-01-18
103A VO Transmission Assembly Oper 910 140300-N0502-01-18 **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 860 Install & r/d 2 studs w/ nuts, 2 coolant outlets and 1 temp sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 870 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 880 Install & r/d small plug w/O-ring, 2 large plugs w/ O-ring and press in small coolant port **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 890 Feed & press vent tube and install rubber hose w/ clip **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 900 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.17**  **$0.82 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 910 Install & r/d 3 large studs, drain plug and cover plug **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **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: 13 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

104A VO Transmission Assembly Oper 920 140300-N0502-01-18
105A VO Transmission Assembly Oper 930 140300-N0502-01-18
106A VO Transmission Assembly Test loop 140300-N0502-01-18
107A VO Transmission Assembly Test 10 140300-N0502-01-18
108A VO Transmission Assembly Test 20 140300-N0502-01-18
109A VO Transmission Assembly Test 30 140300-N0502-01-18 

### 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**

**$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 920 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 930 Load test loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$3.25 $4.17**  **$7.42 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$0.00 $4.17**  **$4.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$3.25 $4.17**  **$7.42 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0** 
110A VO Transmission Assembly Test 40 140300-N0502-01-18
111A VO Transmission Assembly Test 50 140300-N0502-01-18
112A VO Transmission Assembly Oper 940 140300-N0502-01-18
113A VO Transmission Assembly Oper 950 140300-N0502-01-18
114A VO Transmission Assembly Oper 960 140300-N0502-01-18
115A VO Transmission Assembly Oper 970 140300-N0502-01-18
116A VO Transmission Assembly Oper 980 140300-N0502-01-18
117A VO Transmission Assembly Oper 990 140300-N0502-01-18
118A VO Transmission Assembly Oper 1000 140300-N0502-01-18
119A VO Transmission Assembly Oper 1010 140300-N0502-01-18
120A VO Transmission Assembly Oper 1020 140300-N0502-01-18
121A VO Transmission Assembly Oper 1030 140300-N0502-01-18
122A VO Transmission Assembly Oper 1040 140300-N0502-01-18
123A VO Transmission Assembly Oper 1050 140300-N0502-01-18 

## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $4.17**  **$4.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$3.25 $4.17**  **$7.42 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 940 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 950 Unload test loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 960 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 970 Auto oli fill **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.65 $0.10**  **$0.75 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 980 Install & r/d long plug **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 990 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1000 Case washer **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1010 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1020 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.30 $0.10**  **$1.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1030 Unload to rack **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1040 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1050 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  

## 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 3.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$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!**
- - - - **1.1 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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: 14 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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** 


### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 15 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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) **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**  **$0.00 Labor**  **Burden TMC**  **Scrape SG&A**  **Profit ED&T**  **Mark-up Total**  **$58.49 $44.17**  **$102.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$102.66 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: 16 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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: 17 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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) 1A VO Transmission Assembly Oper 5 140300-N0502-01-01 2A VO Transmission Assembly Oper 10 140300-N0502-01-02
3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03
4A VO Transmission Assembly Oper 15 140300-N0502-01-04
5A VO Transmission Assembly Oper 20 140300-N0502-01-05



### 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** 

**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- 6A VO Transmission Assembly Oper 30 140300-N0502-01-06
7A VO Transmission Assembly Oper 40 140300-N0502-01-07
8A VO Transmission Assembly Oper 50 140300-N0502-01-08
9A VO Transmission Assembly Oper 60 140300-N0502-01-09
10A VO Transmission Assembly Oper 70 140300-N0502-01-10
11A VO Transmission Assembly Oper 80 140300-N0502-01-11
12A VO Transmission Assembly Oper 90 140300-N0502-01-12
13A VO Transmission Assembly Oper 100 140300-N0502-01-13
14A VO Transmission Assembly Oper 110 140300-N0502-01-14
15A VO Transmission Assembly Oper 120 140300-N0502-01-15
16A VO Transmission Assembly Oper 130 140300-N0502-01-16
17A VO Transmission Assembly Oper 140 140300-N0502-01-17
18A VO Transmission Assembly Oper 150 140300-N0502-01-18
18A VO Transmission Assembly Oper 160 140300-N0502-01-18
20A VO Transmission Assembly Oper 170 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00** 
- 21A VO Transmission Assembly Oper 180 140300-N0502-01-18
22A VO Transmission Assembly Oper 190 140300-N0502-01-18
23A VO Transmission Assembly Oper 200 140300-N0502-01-18
24A VO Transmission Assembly Oper 210 140300-N0502-01-18
25A VO Transmission Assembly Oper 220 140300-N0502-01-18 **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 18 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

26A VO Transmission Assembly Oper 230 140300-N0502-01-18
27A VO Transmission Assembly Oper 240 140300-N0502-01-18
28A VO Transmission Assembly Oper 250 140300-N0502-01-18
29A VO Transmission Assembly Oper 260 140300-N0502-01-18
30A VO Transmission Assembly Oper 270 140300-N0502-01-18
31A VO Transmission Assembly Oper 280 140300-N0502-01-18**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** 

**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18
34A VO Transmission Assembly Oper 290 140300-N0502-01-18
35A VO Transmission Assembly Oper 300 140300-N0502-01-18
36A VO Transmission Assembly Oper 310 140300-N0502-01-18
37A VO Transmission Assembly Oper 320 140300-N0502-01-18
38A VO Transmission Assembly Oper 330 140300-N0502-01-18
39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
40 VO Transmission Assembly Oper 340 140300-N0502-01-18
41A VO Transmission Assembly Oper 350 140300-N0502-01-18
42A VO Transmission Assembly Oper 360 140300-N0502-01-18
43A VO Transmission Assembly Oper 370 140300-N0502-01-18
44A VO Transmission Assembly Oper 380 140300-N0502-01-18
45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 46A VO Transmission Assembly Oper 390 140300-N0502-01-18
47A VO Transmission Assembly Oper 400 140300-N0502-01-18
48A VO Transmission Assembly Oper 410 140300-N0502-01-18
49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
51A VO Transmission Assembly Oper 420 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 

### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 19 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

52A VO Transmission Assembly Oper 430 140300-N0502-01-18
53A VO Transmission Assembly Oper 440 140300-N0502-01-18
54A VO Transmission Assembly Oper 450 140300-N0502-01-18
55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18**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** 

**150 24.00**  1.00
**150 24.00** 
- **150 24.00** 
-
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
58A VO Transmission Assembly Oper 460 140300-N0502-01-18
59A VO Transmission Assembly Oper 470 140300-N0502-01-18
60A VO Transmission Assembly Oper 480 140300-N0502-01-18
61A VO Transmission Assembly Oper 490 140300-N0502-01-18
62A VO Transmission Assembly Oper 500 140300-N0502-01-18
63A VO Transmission Assembly Oper 510 140300-N0502-01-18
64A VO Transmission Assembly Oper 520 140300-N0502-01-18
65A VO Transmission Assembly Oper 530 140300-N0502-01-18
66A VO Transmission Assembly Oper 540 140300-N0502-01-18
67A VO Transmission Assembly Oper 550 140300-N0502-01-18
68A VO Transmission Assembly Oper 560 140300-N0502-01-18
69A VO Transmission Assembly Oper 570 140300-N0502-01-18
70A VO Transmission Assembly Oper 580 140300-N0502-01-18
71A VO Transmission Assembly Oper 590 140300-N0502-01-18
72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00** 
- **150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00** 
- **150 24.00**  2.00
**150 24.00**  1.00
**150 24.00**  2.00
**150 24.00**  2.00
**150 24.00** 
- 72A VO Transmission Assembly Oper 600 140300-N0502-01-18
73A VO Transmission Assembly Oper 610 140300-N0502-01-18
74A VO Transmission Assembly Oper 620 140300-N0502-01-18
75A VO Transmission Assembly Oper 630 140300-N0502-01-18
76A VO Transmission Assembly Oper 640 140300-N0502-01-18
77A VO Transmission Assembly Oper 650 140300-N0502-01-18 **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 

### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 20 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

78A VO Transmission Assembly Oper 660 140300-N0502-01-18
79A VO Transmission Assembly Oper 670 140300-N0502-01-18
80A VO Transmission Assembly Oper 680 140300-N0502-01-18
81A VO Transmission Assembly Oper 690 140300-N0502-01-18
82A VO Transmission Assembly Oper 700 140300-N0502-01-18
83A VO Transmission Assembly Oper 710 140300-N0502-01-18**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** 

**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  4.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
84A VO Transmission Assembly Oper 720 140300-N0502-01-18
85A VO Transmission Assembly Oper 730 140300-N0502-01-18
86A VO Transmission Assembly Oper 740 140300-N0502-01-18
87A VO Transmission Assembly Oper 750 140300-N0502-01-18
88A VO Transmission Assembly Oper 760 140300-N0502-01-18
89A VO Transmission Assembly Oper 770 140300-N0502-01-18
90A VO Transmission Assembly Oper 780 140300-N0502-01-18
91A VO Transmission Assembly Oper 790 140300-N0502-01-18
92A VO Transmission Assembly Oper 800 140300-N0502-01-18
93A VO Transmission Assembly Oper 810 140300-N0502-01-18
94A VO Transmission Assembly Oper 820 140300-N0502-01-18
95A VO Transmission Assembly Oper 830 140300-N0502-01-18
96A VO Transmission Assembly Oper 840 140300-N0502-01-18
97A VO Transmission Assembly Oper 850 140300-N0502-01-18
98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00 98A VO Transmission Assembly Oper 860 140300-N0502-01-18
99A VO Transmission Assembly Oper 870 140300-N0502-01-18
100A VO Transmission Assembly Oper 880 140300-N0502-01-18
101A VO Transmission Assembly Oper 890 140300-N0502-01-18
102A VO Transmission Assembly Oper 900 140300-N0502-01-18
103A VO Transmission Assembly Oper 910 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00**  1.00


### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 21 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.

104A VO Transmission Assembly Oper 920 140300-N0502-01-18
105A VO Transmission Assembly Oper 930 140300-N0502-01-18
106A VO Transmission Assembly Test loop 140300-N0502-01-18
107A VO Transmission Assembly Test 10 140300-N0502-01-18
108A VO Transmission Assembly Test 20 140300-N0502-01-18
109A VO Transmission Assembly Test 30 140300-N0502-01-18**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** 

**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **30 120.00**  1.00
**30 120.00** 
- **30 120.00**  1.00
110A VO Transmission Assembly Test 40 140300-N0502-01-18
111A VO Transmission Assembly Test 50 140300-N0502-01-18
112A VO Transmission Assembly Oper 940 140300-N0502-01-18
113A VO Transmission Assembly Oper 950 140300-N0502-01-18
114A VO Transmission Assembly Oper 960 140300-N0502-01-18
115A VO Transmission Assembly Oper 970 140300-N0502-01-18
116A VO Transmission Assembly Oper 980 140300-N0502-01-18
117A VO Transmission Assembly Oper 990 140300-N0502-01-18
118A VO Transmission Assembly Oper 1000 140300-N0502-01-18
119A VO Transmission Assembly Oper 1010 140300-N0502-01-18
120A VO Transmission Assembly Oper 1020 140300-N0502-01-18
121A VO Transmission Assembly Oper 1030 140300-N0502-01-18
122A VO Transmission Assembly Oper 1040 140300-N0502-01-18
123A VO Transmission Assembly Oper 1050 140300-N0502-01-18 

## Purchase Part - High Impact Item (Full Cost Mapping) **30 120.00** 
- **30 120.00**  1.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- 

## 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!** 
- 

### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 22 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#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: 23 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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)**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: 24 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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

## HEV Transmission

Time (sec) Levels of complexity Man

Station Auto

station Base

Equipment Category Item Number Equipment

category Item Number Number

of r/d units Spindle #

per r/d unit (5L) # of

pressed parts (9B/9D) **Oper.# Sta.#**  **Assembly Process Reference Photos**  5 Load Load Case to washer pallet 26 M 1 4 4E 10 Auto Washer automation L 1 10 10C Off-line Part washer M 1 10 10A 15 Unload / load Load case to assembly pallet over pins M 1 4 4E 20 Auto Clamp case and rotate to electric box side up L 1 2 5H 1 2 30 Semi- auto Press in Traction motor bearing M 1 1 9D 2

Press in Park lever seal
40 Manual Press in 2 locating dowels for Cover and 2 dowels for Planetary set housing M 1 1 9E 4

Assemble air inlet cover 5A 1 1 Start & rundown (1) bolt
50 Manual Place Park lever rooster comb & bullet assy. Into case L 1 1

Install Park lever shaft thru housing and into rooster comb
60 Manual Hand align rooster comb shaft holes & install pin with pin press tool L 1 1 9E 70 Manual Install 2 park lever springs and run down spring bolt L 1 1 5A 1 1 80 Rotate Rotate housing to gear box side up L 1 052 90 Press in 2 cover mounting dowels L 1 1 9E 2

Assemble 3 bearing shims to 3 bearing bores (all except main transfer gear bore)
100 Semi-auto Load and press 2 tapered bearing races (all except traction motor bore) M 1 1 9D 2 110 Semi-auto Load and press 1 tapered bearing races (all except traction motor bore) M 1 1 9D 2

Load and press 1 ball bearing race into case traction motor bore
120 Manual Install bullet receiver sleeve L 1 1

Install half round bullet locator Position to install parking pawl arm Install parking pawl arm pivot pin with spring
130 Manual Position to install bullet receiver L 1 1 5A 1

Start & rundown 2 bullet receiver mounting screws
140 Manual Position to install oil pump assembly L 1 1 5A 1

Start & rundown 3 oil pump assembly mounting bolts Install short trans passage tube 0587 150 Manual Install long oil pump tube L 1 1 5A 1

1 of 7

## Position 2 tube mounting brackets Start & rundown 2 long oil pump bracket mounting bolts

160 On-line accumulator Powered roller section L 1 051 170 Auto Repair bay entrance / exit L 1 05

180 On-line accumulator Powered roller section L 1 051 190 Rotate Rotate case to electric box side up L 1 052 200 Manual Install planetary assembly 3856 L 1 1

Install oil pump drive assembly 3852 Install planetary housing cover 3848 210 Manual Place, start & rundown 7 planetary housing cover mounting bolts L 1 1 5A 1 220 Manual Poisition generator speed sensor wire harness thru case opening 3681 L 1 1

Attach wire harness to sensor Install speed sensor - Generator 3826 230 Manual Place, start & rundown 3 bolts L 1 1 5A 1 240 Manual Position (2) generator & motor isolators (at pass thru case) L 1 1 5A 1

Place, start & rundown 2 bolts
250 Manual Poisition motor speed sensor wire harness thru case opening L 1 1

Attach wire harness to sensor
260 Manual Install speed sensor - Traction Motor 3826 L 1 1 5A 1

Place, start & rundown 3 bolts
270 Manual Install generator assembly with terminal wires down 3807 L 1 1 5A 2

Poisition speed sensor wire clip on (1) bolt boss before rundown Place, start & rundown 3 bolts
280 Manual Install traction motor assembly with terminal wires down 3807 L 1 1 5A 1

Poisition speed sensor wire clip on (1) bolt boss before rundown Place, start & rundown 3 bolts Off-line Manual - Load cover to gage station L 1 7 7B Gage Station Measure case rail to generator and motor (2) bearings

Measure cover rail to (2) bearing pockets (depth) Manual - Select shims grease and install in cover Off-line RTV cover L 1 6 6A 290 On-Line Pick, rotate and place cover over dowels to electric motor side of case L 1 052 300 Manual Place, start & rundown 10 cover mounting bolts L 2 1

Manual Place, start & rundown 10 cover mounting bolts

2 of 7

## 310 Auto R/d 20 cover bolts/studs M 1 2 5K 1 20 320 Rotate Rotate housing to gear box side up L 1 052

330 On-line accumulator Powered roller section L 1 051
Gage Station Check for no end play condition and torque to turn on generator and motor

shafts 3803 H 1 7 7D 340 Manual Repair bay entrance / exit L 1 05

350 On-line accumulator Powered roller section L 1 051 360 Manual Poisition traction speed sensor wire clip on (1) bolt boss before rundown L 1 1 5A 1

Place, start & rundown 1 bolt Poisition motor speed sensor wire clip bracket on (2) bolt bosses before rundown Place, start & rundown 2 bolts Attach motor speed sensor wire connector clip to bracket 3765 370 Manual Install (6) terminal leads thru case 3757 L 1 1 5A 1

Place, start & rundown 1 bolt per lead
380 Manual Position motor & generator wires to terminal leads 3757 L 1 1 5A 1

Place, start & rundown 1 bolt per wire Off-line Manual load semi-auto press stations M 1 1 9D 2

Press inner roller bearings into both ends generator transfer shaft Press outer ball bearing on cover side generator transfer shaft and tapered bearing on case side

390 Semi-auto Align and press traction motor transfer shaft thru roller bearing in case then

OD spline into traction rotor shaft ID spline M 1 1 9D 2 400 Semi-auto Press transfer shaft over the generator planetary shaft M 1 1 9C

410 Manual Align and assemble diferential assembly into case (roller bearing into race in

case) L 1 1 Offline Manual load semi-auto press station

Press taper bearing on case side of output shaft Press outer gear set onto transfer gear output shaft Offline Manual load semi-auto press station

Press taper bearing on cover side of output shaft Place, start & rundown 1 nut on end of output shaft
420 Manual Install output shaft aseembly into case (roller bearing into race) 3782/3751 L 1 1 430 Semi-auto Press roller bearing on to traction motor transfer shaft (cover side) 3780 L 1 1 9C

440 On-line accumulator Powered roller section L 1 051

3 of 7

## 450 Gage Station

online Measure height from case rail to taper bearing race on differential, output &

transfer shafts H 1 7 7B Gage Station Manual - Load bell housing to gage station H 1 7 7C Offline Measure from cover rail to above mentioned (3) bearing pockets (depth) Dial Machine Manual - Select shims and install in cover then load 3 races

Semi-auto - Press (3) races into cover Off- line Manual L 1 1 5A 1

Install oil diffuser Place, start & rundown 3 bolts Off-line RTV gear side of Bell housing M 1 1 6A 460 Auto Pick, rotate and place bell housing over dowels to gear side of case M 1 1 3D 470 Manual Place, start 11 bolts (bell housing to gear side of case) L 2 1

Manual Place, start 10 bolts (bell housing to gear side of case)
480 Auto Rundown 21 bolts M 1 1 5K 1 21

490 On-line accumulator Powered roller section L 1 051 500 Online Automatic torque to turn output shaft H 1 1 7D Gage Station 510 Manual Repair bay entrance / exit L 1 05

520 On-line accumulator Powered roller section L 1 051 530 Rotate Case Electronic face down L 1 052 540 Semi-Auto Install seal in output shaft bores on bell housing side and gear box side M 1 1 9D 3

Install seal in input shaft bore on bell housing side
550 Rotate Case Electronic face up L 1 052 560 Manual Install oil cooler gasket 3701 L 2 1 5A 2

Install oil cooler cover Place, start & rundown 19 bolts
570 Manual Install (2) dowels L 1 1 9D

Install electronic housing gasket 3696 580 Manual Position electronic housing over dowels in case & start two bolts L 2 1 5A 1

Manual Place, start 10 bolts (electronic housing to case)
590 Manual Place, start 10 bolts (electronic housing to case) L 2 1 5A 2

Manual Place, start 10 bolts (electronic housing to case)
600 Auto Rundown 32 bolts (electronic housing to case) H 1 2 5K 2

4 of 7

## 610 Manual Install (2) current sensor bars over terminal leads L 1 1 5A 1 Place, start & rundown 2 bolts into each current sensor 3683, 3674 620 Manual Install traction motor control unit and r/d 6 bolts 3627 L 1 1 5A 1 630 Manual Install generator control unit and r/d 6 bolts 3627 L 1 1 5A 1 640 Manual Install (Denso) control unit and r/d 4 bolts 3627 L 1 1 5A 1 650 Manual Install (3) bus bars between traction control unit and current sensor bar 3627 L 1 1 5A 1

Rundown 2 bolts each
660 Manual Install (3) bus bars between generator control unit and sensor bar 3627 L 1 1 5A 1

Rundown 2 bolts each
670 Manual Route all wires coming off control units before installing cover L 1 1

Install wire harnesses into each of the traction & generator control units
680 Offline Main control housing build loop L 4 11 11A

1 - Load housing to fixture and install capacitor box 2 - Place, start & rundown 8 screws 3 - Rotate control unit housing to top side up and install 2 black box 4 - Place, start & rundown 3 screws each box 5 - Install (1) green circuit board and r/d 6 screws 6 - Rundown (6) screws into curcuit board and install harness brackets 7 - Rundown 4 bracket screws and mount wire clips 8 - unload main control assembly 3625 690 Manual Install main control unit housing 3623 L 1 1 5A 1

Place, start & rundown 6 bolts

700 Manual Fasten (3) wires into clips and insert (4) wire connectors into curcuit board L 1 1

710 Manual Install Short bar - Install left hand hole over right hand stud w/nut at upper

box ? (with wire) and right hand hole goes over left stud w/nut on lower box and r/d nuts 3581 L 1 1 5A 1

720 Manual install Medium bar - Install left hand & center hole to lower box ? w/ 2 bolts,

and right hand hole goes over left stud w/nut on upper box and r/d 3581 L 1 1 5A 1

730 Manual Long bar - Install right hand hole over lower box right stud w/nut and left hand

hole w/bolt and r/d 3581 L 1 1 5A 1 740 Manual Connect (1) wire to lower black control box on left lower lug with bolt L 1 1 5A 1

Connect (1) wire to lower black control box on right lower lug with bolt 3607 Place, start & rundown 2 bolts Place, start & rundown 2 bolts at lugs to connect upper to lower black box 3581 L 1 1 5A 2 750 Manual Install Main Power TACM connector (orange) to end of electronics housing,

insert wiring thru holes in housing and position connector 3517 Place, start & rundown 3 bolts

5 of 7

## Terminate (2) wires to studs Place, start & rundown 2 nuts
760 Manual Install (2) TACM#2 connectors L 1 1 5A 1

Place, start & rundown 1 bolt each 3509 770 Manual Install large harness guide

Place, start & rundown 4 screws 3518 L 1 1 5A 1 780 Manual Insert (5) harness clips to harness guide

Install and rundown Ground Stud with nut
790 Manual Position (3) wire harnesses with (7) connectors L 1 1 5A 1

Terminate/plug in (9) connectors (includes 2 existing connectors) 3516, 3518 800 Manual Install cork gasket on top of electronic housing L 1 1

810 Manual Position Cover & Tab Assembly and start and r/d to zero torqe 2 studs bolts L 1 1 5A 1 820 Manual Place, start & rundown to zero torque 8 bolts & 2 stud bolts L 2 1 5A 2

Manual Place, start & rundown to zero torque 8 bolts & 2 stud bolts
830 Auto Auto rundown 22 fasteners M 1 1 5K 22 840 Rotate Rotate pallet to shift lever area L 1 052 850 Manual Install Shift lever indicator housing L 1 1 5A 1

Place, start & rundown 2 bolts 3511 Install Shift Lever/Locking Clamp Place, start & rundown 1 nut
860 Manual Install and rundown (2) Studs with nuts L 1 1 5A 2

Install & rundown (2) Coolant Outlets Install & rundown (1) Temperature Sensor 3510, 3511 870 Rotate 180 Rotate pallet 180 Degrees L 1 052 880 Manual Install & rundown Small Plug w/O-Ring (rear cover) L 1 1 5A 1

Press in Small Coolant Port 3507 Install & rundown (2) Large Torques Plug w/O-Ring (cover)
890 Manual Feed and press Vent Tube and install Rubber Hose with clip L 1 1 9E 3507 900 Rotate 180 Differential end up L 1 052 910 Manual Install and rundown (3) Large A Studs (Torques) on rear of cover L 1 1 5A 3

Install and rundown Drain Plug (Plug Wide) Install and rundown Cover Plug (Plug Wide)

920 On-line accumulator Powered roller section L 1 051 930 Auto Load to test loop M 1 4 4E

6 of 7

## Automation L 2 1 051 Test Test loop Automation L 5 1 051

Rotate L 1 052 T10 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051 Rotate L 2 052 T20 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051 Rotate L 2 052 T30 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051 Rotate L 2 052 T40 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051 Rotate L 2 052 T50 Perform functional test (includes partial oil fill) 5 stations H 1 7 7D

Automation L 2 1 051 Rotate L 2 052

940 On-line accumulator Powered roller section L 1 051 950 Auto Load from test loop automation M 1 4 4E

Automation L 2 1 051

960 On-line accumulator Powered roller section L 2 051 970 Auto Final oil fill H 1 7 7J 980 Manual Install and rundown Long Plug L 1 1 5A 1

990 On-line accumulator Powered roller section L 2 051 1000 Auto Wash system H 1 10 10B

1010 On-line accumulator Powered roller section L 1 051

1020 On-line accumulator Powered roller section L 1 051 1030 Manual Unload to shipping dunnage M 1 1 4G

1040 On-line accumulator Powered roller section L 1 051

1050 On-line accumulator Powered roller section L 1 051

7 of 7

# $

**Z.** 

# Generic 36" x 36" pallet, (3 per section) 4 feet wide in floor transport. 1/2 Idle station, pre-station, work station, empty station and 1/2 idle station. 14' overall length. Overall floor space to be 10' wide (2' to contain panel, 4' line width, 4' work
**Z.05 Z.05**  **Transport** 

# Corners, cross transfers 4 feet wide in floor transport x 4 feet long. 16 square feet 285,000

**Z.051 Z.051**  **Transport** 

# Straight automation with pallet stops / controllers 4 feet wide in floor transport x 10 feet long. 40 square feet with 3 pallet stops and level controllers 124,000

**Z.052 Z.052**  **Transport** 

# Rotate 4 feet wide in floor transport x 6 feet long. Automation capable of rotating pallet as required. 24 square feet 165,000

Z.1 **Z.1 Manual Work Station**  **Single work station to assemble part / parts**  

# Pre-stop, station stop, idle 10 ' feet of transfer automation, control panel with part status lights and release button. Includes 2 pallets 140,000

Z.2 **Z.2 Auto Work Station**  **Single work station to assemble part / parts**  

# 4 feet wide in floor transport. 1/2 Idle station, pre-station, work station, empty station and 1/2 idle station. 14' overall length. Overall floor space to be 12' wide (3' to contain panel, 4' line width, 5' work space) by 14' long - 188 square feet and i 202,000 **Item Equipment Category Name**  **Equipment Description Equipment Specification** 

**OEM Transmission Assembly**

**Equipment Primary**  **Equipment Cost** 

# Z.3 **Z.3 Dedicated Part Handling**  **Equipment (e.g. Pick and Place)**  

# 3A **3A** 

# Vertical and Lateral

Movement (0-10lbs) Light weight part pick up and load to palletized assembly Overhead frame with linear vertical / horizontal movement. 50,000
3B **3B** 

# Vertical, Lateral, Single

Axis Rotation Movement (0-10lbs) Light weight part pick up, rotate and place to palletized assembly Overhead frame with linear vertical / horizontal / rotational movement. 65,000

3C **3C** 

# Vertical and Lateral

Movement (11-40lbs) Medium weight part pick up and load to palletized assembly Overhead frame with linear vertical / horizontal movement. 60,000

3D **3D** 

# Vertical, Lateral, Single

Axis Rotation Movement (11-40lbs) Medium weight part pick up, rotate and place to palletized assembly Overhead frame with linear vertical / horizontal / rotational movement. 75,000

3E **3E** 

# Vertical and Lateral

Movement (40+lbs) Heavy weight part pick up and load to palletized assembly Overhead frame with linear vertical / horizontal movement. 80,000

3F **3F** 

# Vertical, Lateral, Single

Axis Rotation Movement (40+lbs) Heavy weight part pick up, rotate and place to palletized assembly Overhead frame with linear vertical / horizontal / rotational movement. 100,000

4 **4 Part Handling** 

**Equipment** 

# 4A **4A** 

# Robotic Handling

Equipment (0-5lbs) Multi-positional movement Overhead frame or stand alone base with multi-positional movement. 75,000
4B **4B** 

# Robotic Handling

Equipment (5-10) Multi-positional movement Overhead frame or stand alone base with multi-positional movement. 75,000 4C **4C** 

# Robotic Handling

Equipment (10-20lbs) Multi-positional movement Overhead frame or stand alone base with multi-positional movement. 134,000
4D **4D** 

# Robotic Handling

Equipment (20-45) Multi-positional movement Overhead frame or stand alone base with multi-positional movement. 186,000
4E **4E** 

# Robotic Handling

Equipment (45-75) Multi-positional movement Overhead frame or stand alone base with multi-positional movement. 270,000

# 4F **4F** 

# Robotic Handling Equipment (75-150) Multi-positional movement Overhead frame or stand alone base with multi-positional movement. 321,000 4G **4G** 

# Manual Handling

Equipment (75-250) Multi-positional movement Overhead frame with fixed-positional movement manually controlled 89,000
5 **5 Fastening Equipment** 


# 5A **5A** 

# Single Spindle -pneumatic

- Manual Hand controlled pneumatic spindle Tool holding rack or overhead fixture with balancer. 15,000

5B **5B** 

# Single Spindle -pneumatic

- semi- auto Manual push button started pneumatic spindle Horizontal, vertical or angular fixture / frame. Tool is manual started with push buttons - auto release. 22,000 5C **5C** 

# Single Spindle -pneumatic

- auto Automatic station Horizontal, vertical or angular fixture / frame. Auto started and released 55,000 5D **5D** 

# Single Spindle - Electric -

Manual Hand controlled electric spindle Tool holding rack or overhead fixture with balancer. 18,000 5E **5E** 

# Single Spindle - Electric -

semi-auto Manual push button started electric spindle Horizontal, vertical or angular fixture / frame. Tool is manual started with push buttons - auto release. 25,000 5F **5F** 

# Single Spindle - Electric -

auto Automatic station Horizontal, vertical or angular fixture / frame. Auto started and released 55,000 5G **5G** 

# Multi Spindle -pneumatic -

semi auto Manual push button started pneumatic spindle Horizontal, vertical or angular fixture / frame. Tool is manual started with push buttons - auto release. 40,000 5H **5H** 

# Multi Spindle -pneumatic -

auto Automatic station Horizontal, vertical or angular fixture / frame. Auto started and released 55,000 5J **5J** 

# Multi Spindle - Electric -

semi-auto Manual push button started electric spindle Horizontal, vertical or angular fixture / frame. Tool is manual started with push buttons - auto release. 40,000 5K **5K** 

# Multi Spindle - Electric -

auto Automatic station Horizontal, vertical or angular fixture / frame. Auto started and released 55,000 5L **5L** 

# Multiple parts cost Additional cost per spindle 22,000
6 **6 Dispensing Equipment** 

# 6A **6A** 

# RTV Dispensing Equipment - Standard Automatically dispense RTV to / on part Automatic stand alone system 36,000 6B **6B** 

# Fluid Dispensing

Equipment - Standard Automatically fill engine Automatic stand alone system with remote oil storage. 50

7 **7 On-line Test/Gauging** 



# 7A **7A** 

# Precision Measuring

Machine -MiD (eg. Shim selection) Dedicated system to determine bearing shims Automatic stand alone system 750,000

7B **7B** 

# Precision Measuring

Machine - High (e.g. dual measuring ) Dedicated system to check cover rail to bearing shaft for clearances Automatic stand alone system 1,350,000

7C **7C** 

# Precision Measuring

Machine - High (e.g. dual measuring ) Dedicated system to check cover rail to bearing shaft for clearances Semi-automatic stand alone system 1,350,000

7D **7D** 

# Precision Measuring

Machine - High (e.g. Functional Test) Dedicated system to fill transmission and verify functions Automatic stand with remote fluid fill system. 1,265,000

7E **7E** 

# Rotate Measuring

Machine (e.g. Torque to Turn) Dedicated system to measure rotational torques Automatic stand alone system 265,000

7F **7F** 

# Lateral Displacement

Measuring Machine (e.g. Part Presence/Orientation) Dedicated system to measure / check part present or part orientation. Automatic stand alone system 73,000

7G **7G** 

# Visual (e.g. Part

Presence/Orientation) Dedicated visual systen to determine part presence / orientation. Automatic stand alone system 47,000
7H **7H** 

# Air Test Dedicated sytem to air test, plugs or surfaces for leaks Automatic stand alone system 79,000 7J **7J** 

# Final oil fill Dedicated system final fill transmission Automatic stand alone system 225,000

# 7K **7K** 

# Multiple parts cost Additional cost per part 11,000

8 **8 Feeders** 


# 8A **8A** 

# Single part Automatically feed part to load mechanism Automatic stand alone system 36,000 8B **8B** 

# Multiple parts Automatically feed part to load mechanism Automatic stand alone system 50,000 8C **8C** 

# Multiple parts cost Additional cost per part 7,000
9 **9 Press stations** 


# 9A **9A** 

# Single part - High Automatically press single bearing or race Automatic stand alone system 189,000 9B **9B** 

# Multiple parts cost Automatically press single bearing or race Additional cost per part 156,000 9C **9C** 

# Single part - Med Semi-automatically press single bearing or race Manual load and auto press station 97,000 9D **9D** 

# Multiple parts cost Semi-automatically press multiple bearing or race Additional cost per part 77,000 9E **9E** 

# Multiple part - Low Manually press multiple parts (dowels) Manual tooling to press dowels/ plugs 10,000

10 **10 Washers & automation** 


# 10A **10A** 

# Ferris Wheel style Automatic self contained parts washer Automatic stand alone system 450,000 10B **10B** 

# Final Assebly washer Automatic flow thru parts washer Automatic stand alone system with robots 1,100,000

# 10C **10C** 

# Washer pallet automation Automation to transfer part / pallet from rack to washer; washer to assembly line Generic 24" x 24" pallet, (4 per section) 3 feet wide on floor transport. Includes pallet stops and controls. 10 overall length. Overall floor space to be 5' wide x 10' long - 50 square feet. **Note! 6 sections required - price reflects 6** 330,000

11 **11** 

# Sub-assembly loop - Low

11A **11A** 

# Sub-assembly loop - Low Off-line assembly system (8 people required) Automation to assembly main control housing. Low tech with simple pallets, manual r/d tools and manual load / unloading of parts. No testing required 480,000

# $ **Square Feet Square Feet** 



# 45,000 16 12
45,000 40 12
45,000 24 12

40,000 140 50

140 **Primary Equipment Facility**  **Floor Space Process** 

**Support Facility Floor**  **Space**



# Pallets @ $30k each.

Cost is $8k /foot for automation with controls **Process Support**  **Equipment Costs** 

# 0 10 0

0 10 0

0 15 0

0 18 0

0 25 0

0 25 0

0 0 0 0 0 0 0 10 0 0 16 0 0 30 0

# 0 60 0

132,000 2 800

0 0 0

0 0 0 0 20 0 0 0 0 0 0 0 0 30 0 0 30 0 0 50 0 0 30 0 0 50 0 0 1 0

# 0 50 0

85,000 10 150

0 50 0

0 150 0

0 150 0
95,000 300 150

0 10 0

0 10 0

0 10 0
0 9 0

50

# 0 1 0

0 12 0 0 12 0 0 1 0

65,000 4 65 25,000 2 5 65,000 4 65 25,000 2 5 5,000 2 2

100,000 300 120 75,000 400 120

# 180,000 300 150

121,000 500 400

# Transmission Assembly

**Volume:** 450,000 year **Work pattern Work pattern** 



# 48 Weeks 48 Weeks 5 Days 

# 5 Days 

# 7.2 Hours av ailable time per shift 

# 7.2 Hours av ailable time per shift 

# 1 **Shift per week** 

# 2 **Shift per week** 

# 36 Hours av ailable per week 

# 72 Hours av ailable per week 

# 1728 Hours av ailable per year 

# 3456 Hours av ailable per year 

# 260 Parts per hour at 100% efficiency 

# 130 Parts per hour at 100% efficiency 

# 302 Parts per hour ar 85% efficiency 

# 151 Parts per hour ar 85% efficiency 12 Cycle time is seconds 24 Cycle time is seconds 

# 0.2 Minutes 

# 0.4 Minutes **System Design Concept** Palletized with simple fixtures designed for heavy parts Transport will be powered rolers Electric controls will be simple - colored light for QC control Overhead pneaumatic lift assits Structured packaging

# Parts per hour at 100% efficiency