### Page:1 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

# 021100 Electric Motor & Controls Subsy **stem - Traction & Generator Motor Sensors**
1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 2 **01 Traction and Generator Motors**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 3 **02 Power Electronic Components and Assemblies**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 4 **03 Control Modules**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **04 Traction and Generator Motor Sensors**  **26.67 $**  **17.96**

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

# 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)

6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 7 **10 Plugs**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 8 **15 Switches**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 9 **72 Electrical Housings/Support Structure**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 10 **75 Brackets**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 13 **90 Bearing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 14 **91 Shims**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 15 **99 Miscellaneous**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 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: 8/23/2012 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)

**26.67 $**  **17.96**

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### -

**$ -** 

**$ -** 

**$ -** 

**$ 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: 8/23/2012 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: 8/23/2012 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**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

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

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

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

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

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

$
-

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

### E1 **65** 26.67 $ 17.96

$ 20.02

$ **64.66**

**$** 0.36

$ 4.22

$ 3.93

$ 1.75

$ **10.26**

**$** 0.33

$ **75.24**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 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: 8/23/2012 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: 8/23/2012 DRAFT



# 021100 Electric Motor & Controls Subsy **stem - Traction & Generator Motor Sensors**
1 **00** 2 **01** 3 **02** 4 **03** 5 **04** 

# 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

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 26.67** 

**$ 17.96** 

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ -** 

**$ -** 

**$ 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** 



### 6 **05** 7 **10** 8 **15** 9 **72** 10 **75** 11 **80** 12 **85** 13 **90** 14 **91** 15 **99** 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: 8/23/2012 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** 



### - **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 26.67

**$ 17.96** 

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$ 0.33** 

**$ 75.24** 

**$ -** 

**$ -** 

**$**



### 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: 8/23/2012 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: 8/23/2012 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: 8/23/2012 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: 8/23/2012 DRAFT



# 021100 Electric Motor & Controls Subsy **stem - Traction & Generator Motor Sensors**
1 **00** 2 **01** 3 **02** 4 **03** 5 **04** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### -

**$**

**- $** 

**- $** 

**- $** 

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



### 6 **05** 7 **10** 8 **15** 9 **72** 10 **75** 11 **80** 12 **85** 13 **90** 14 **91** 15 **99** 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: 8/23/2012 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: 8/23/2012 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: 8/23/2012 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: 8/23/2012 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 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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



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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 

# 021100 Electric Motor & Controls Subsy **stem - Traction & Generator Motor Sensors**
1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**Sub-Subsystem 

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 2 **01 Traction and Generator Motors**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:2 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 3 **02 Power Electronic Components and Assemblies**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:3 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 4 **03 Control Modules**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:4 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 5 **04 Traction and Generator Motor Sensors**  **26.67 $**  **17.96**

**$ 20.02** 

**$ 64.66** 

**$ 0.36** 

**$ 4.22** 

**$ 3.93** 

**$ 1.75** 

**$ 10.26** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** A1 Speed Sensor Asm., Generator 02 # 04
- N0502
- 01 1 Full 1 

### 1.89 $ 1.98

$ 3.72

$ **7.60**

**$** 0.04

$ 0.49

$ 0.46

$ 0.19

$ **1.18**

**$** A2 Speed Sensor Asm., Traction Motor 02 # 04
- N0502
- 02 1 Full 1 

### 3.06 $ 1.93

$ 3.81

$ **8.80**

**$** 0.04

$ 0.57

$ 0.53

$ 0.22

$ **1.36**

**$** A3 Current Sensor, 22 02 # 04
- N0502
- 03 1 Full 1 

### 10.16 $ 6.77

$ 6.00

$ **22.93**

**$** 0.11

$ 1.49

$ 1.38

$ 0.57

$ **3.55**

**$** A4 Current Sensor, 75 02 # 04
- N0502
- 04 1 Full 1 

### 10.06 $ 6.77

$ 6.00

$ **22.83**

**$** 0.11

$ 1.48

$ 1.37

$ 0.57

$ **3.54**

**$** A5 Ballast Resistor, Control Unit 02 # 04
- N0502
- 05 1 Full 1 Commodity price with Cost Element Breakout 

### 1.50 $ 0.50

$ 0.50

$ **2.50**

**$** 0.05

$ 0.17

$ 0.20

$ 0.20

$ **0.62**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:5 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 7 **10 Plugs**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:6 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 8 **15 Switches**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:7 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 9 **72 Electrical Housings/Support Structure**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 10 **75 Brackets**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:8 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:9 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:10 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 13 **90 Bearing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 14 **91 Shims**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:11 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 15 **99 Miscellaneous**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

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

### Page:12 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 16 **na na**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 17 **na na**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 18 **na na**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

26.67 $ 17.96

$ 20.02

$ **64.66**

**$** 0.36

$ 4.22

$ 3.93

$ 1.75

$ **10.26**

**$**

**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) 

## No

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

### Page:13 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

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

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

# 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)

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

### Page:14 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0 **n/a n/a**  

# 021100 Electric Motor & Controls Subsy **stem - Traction & Generator Motor Sensors**
1 **00 Assembly of Misc Electric Motor & Controls Subsystem** Sub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent



# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### 2 **01 Traction and Generator Motors**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:15 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 3 **02 Power Electronic Components and Assemblies**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:16 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 4 **03 Control Modules**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:17 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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

5 **04 Traction and Generator Motor Sensors** 

A1 Speed Sensor Asm., Generator 02 # 04
- N0502
- 01 1 Full 1 

### A2 Speed Sensor Asm., Traction Motor 02 # 04
- N0502
- 02 1 Full 1 

### A3 Current Sensor, 22 02 # 04
- N0502
- 03 1 Full 1 

### A4 Current Sensor, 75 02 # 04
- N0502
- 04 1 Full 1 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$ 0.33**  **$ 75.24** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0.10 $ **8.87**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0.10 $ **10.27**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0.05 $ **26.53**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0.05 $ **26.42**

**$ -** 

**$ -** 

**$ -** 

**$** 

### A5 Ballast Resistor, Control Unit 02 # 04
- N0502
- 05 1 Full 1 Commodity price with Cost Element Breakout



### 6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  0.03 $ **3.15**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:18 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 7 **10 Plugs**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:19 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 8 **15 Switches**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:20 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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

9 **72 Electrical Housings/Support Structure**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 10 **75 Brackets**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:21 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:22 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

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

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:23 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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

13 **90 Bearing Elements**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 14 **91 Shims**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:24 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 15 **99 Miscellaneous**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$**

- $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:25 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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

16 **na na**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 17 **na na** 
18 **na na** 

**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) 

## No - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 0.33 $ **75.24**

**$ -** 

**$ -** 

**$ -** 

**$**



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

### Page:26 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

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

Factor (Default =1) 

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

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


# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

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



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

### Page: 1 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Speed Sensor Asm., Generator**  

## Part Number: **021104-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 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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** 

### B 

## Purchase Part - High Impact Item (Full Cost Mapping)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.006 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 H Lower Cover, Speed Sensor, Gen **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **529 0.5**  **1 1**  0.0080 **$6.07 $41.48**  **$16.39 $16.39**  **$0.05 $0.04**  **$0.03 $0.12**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.12 $0.12**  **$0.05**
5 H Upper Cover, Speed Sensor, Gen **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **529 0.5**  **1 1**  0.0130 **$6.07 $41.48**  **$16.39 $16.39**  **$0.08 $0.04**  **$0.03 $0.15**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.15 $0.15**  **$0.08**
6 H Wire Guide Housing, Speed Sensor, Gen **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **489 0.5**  **1 1**  0.0320 **$6.07 $41.48**  **$16.39 $16.39**  **$0.19 $0.04**  **$0.03 $0.27**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.27 $0.27**  **$0.19**
7 H Plate , Asm., Generator **1** Coat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Conformal Coat, UV Cure **103 0.5**  **1 1**  0.000 **$6.07 $36.21**  **$28.33 $28.33**  **$0.00 $0.18**  **$0.28 $0.45**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.45 $0.45**  **$0.00**
8 **1** Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, HC, Base **103 0.25**  **1 1**  0.000 **$0.00 $37.35**  **$45.00 $45.00**  **$0.00 $0.09**  **$0.44 $0.53**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.53 $0.53**  **$0.00**
9 **8** Stamping T1 Assembly, Mark-up Applied @ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS **6000 2**  **1 1**  0.102 **$0.75 $42.73**  **$24.60 $24.60**  **$0.08 $0.01**  **$0.00 $0.09**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.09 $0.76**  **$0.61**
10 **1** Rotor Stacking T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Cut/Punch/Forming Operator Elec. Assembly, MC, Base **345 0**  **4 1**  0.000 **$0.00 $42.73**  **$30.00 $120.00**  **$0.00 $0.00**  **$0.35 $0.35**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.35 $0.35**  **$0.00** 10 **1** Rotor Stacking @ Bottom. Not Applicable Cut/Punch/Forming Operator Elec. Assembly, MC, Base **345 0**  **4 1**  0.000 **$0.00 $42.73**  **$30.00 $120.00**  **$0.00 $0.00**  **$0.35 $0.35**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.35 $0.35**  **$0.00**
11 **1** Winding T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, HC, Base **136 4**  **4 1**  0.000 **$0.00 $37.35**  **$45.00 $180.00**  **$0.00 $1.10**  **$1.33 $2.42**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$2.42 $2.42**  **$0.00**
12 **1** Solder T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Elec. Assembly, LC **369 2**  **2 1**  0.000 **$0.00 $44.96**  **$100.00 $200.00**  **$0.00 $0.24**  **$0.54 $0.79**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.79 $0.79**  **$0.00**
13 **1** Potting T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, LC **277 0.5**  **1 1**  0.000 **$0.00 $37.35**  **$100.00 $100.00**  **$0.00 $0.07**  **$0.36 $0.43**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.43 $0.43**  **$0.00**
14 **1** Vibration Weld T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Elec. Assembly, LC **327 0.5**  **1 1**  0.000 **$0.00 $44.96**  **$100.00 $100.00**  **$0.00 $0.07**  **$0.31 $0.37**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.37 $0.37**  **$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**



### 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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Speed Sensor Asm., Generator**  

## Part Number: **021104-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**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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** 

### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**


### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 
1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub
Assembly. 2 H Potting Compound, Speed Sensor **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01** 3 H Terminal Inserts, Speed **6** S **$0.00** $0.02 **$0.00 $0.12**  **$0.12** 4 H Copper Wire, Speed Sensor, Gen **3** S **$0.00** $0.19 **$0.00 $0.56**  **$0.56** 5 H Bolt, Speed Sensor, Generator **3** Mounting Hardware into Trans S **$0.00** $0.09 **$0.00 $0.27**  **$0.27** 6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### Assembly. "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to



### 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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Speed Sensor Asm., Generator**  

## Part Number: **021104-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**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 Material**  **$1.89**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$7.60 T1 or OEM Total Manufacturing Cost:**  **$1.89 $1.98**  **$3.72 $7.60**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $7.60** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$0.04 $0.49**  **$0.46 $0.19**  **$1.18 Base Cost Impact to Vehicle:**  **$1.89 $1.98**  **$3.72 $7.60**  **$0.04 $0.49**  **$0.46 $0.19**  **$1.18 $8.77**  **$0 $0**  **Packaging Cost: $0.10**  **Net Cost Impact to Vehicle: $8.87** 

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 
**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### 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. 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: 4 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



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

H Lower Cover, Speed Sensor, Gen H Upper Cover, Speed Sensor, Gen H Wire Guide Housing, Speed Sensor, Gen H Plate , Asm., Generator **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $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**  **$0.04 $0.03**  **$0.12 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  One Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6.8 1 1 6.8 **1.0 1.0**  **$0.04 $0.03**  **$0.15 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  One Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6.8 1 1 6.8 **1.0 1.0**  **$0.04 $0.03**  **$0.27 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  One Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 7.361 1 1 7.361 **1.0 1.0**  **$0.18 $0.28**  **$0.45 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Add conformal coating, drip varnish **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 35 1 1 35 **1.0 1.0**  **$0.09 $0.44**  **$0.53 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  1 person 2 station 30 sec test **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 35 1 1 35 **1.0 1.0**  **$0.11 $0.03**  **$0.76 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Progressive stamping die in-line with automatic rotor disc stacking equipment. **5 2**  **10 100**  **47 4700**  **766 4.70**  **85% 901**  **4.00** 0.6 2 1 0.6 **1.0 1.0**  **$0.00 $0.35**  **$0.35 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Rotor stacking equipment, direct feed from stamping press, orientate, stack and press into place **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 183 1 1 41.8 **1.0 4.0**  Rotor stacking equipment, direct feed from stamping press, orientate, stack and press into place **$1.10 $1.33**  **$2.42 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  4 station 4 person winding asm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 106 1 1 106 **1.0 4.0**  **$0.24 $0.54**  **$0.79 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  2 station 2 person six welds per asm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 39 1 1 19.5 **1.0 2.0**  **$0.07 $0.36**  **$0.43 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Apply potting compound **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0**  **$0.07 $0.31**  **$0.37 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Vibration weld **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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: 5 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



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



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00** H Potting Compound, Speed Sensor H Terminal Inserts, Speed H Copper Wire, Speed Sensor, Gen H Bolt, Speed Sensor, Generator **$0.01 $0.12**  **$0.56 $0.27**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $1.98**  **$3.72 $7.60**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 2**  **$7.60** 

### 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: 7 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



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

H Lower Cover, Speed Sensor, Gen H Upper Cover, Speed Sensor, Gen H Wire Guide Housing, Speed Sensor, Gen H Plate , Asm., Generator **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

**#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **529 6.80**  0.50
**529 6.80**  0.50
**489 7.36**  0.50
**103 35.00**  0.50
**103 35.00**  0.25
**6000 0.60**  2.00
**345 10.44** 
- **136 26.50**  4.00
**369 9.75**  2.00
**277 13.00**  0.50
**327 11.00**  0.50 **#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: 8 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

H Potting Compound, Speed Sensor H Terminal Inserts, Speed H Copper Wire, Speed Sensor, Gen H Bolt, Speed Sensor, Generator



### 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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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

### Page: 1 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Speed Sensor Asm., Traction Motor**  

## Part Number: **021104-N0502-02** 

## 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 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574 **10 North America**  **North America FOB Ship Point**  **47 450,000**  **1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Parallel HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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** 

### B 

## Purchase Part - High Impact Item (Full Cost Mapping)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.006 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 H Lower Cover, Speed Sensor, Traction Motor **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **529 0.5**  **1 1**  0.0170 **$6.07 $41.48**  **$16.39 $16.39**  **$0.10 $0.04**  **$0.03 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.10**
5 H Upper Cover, Speed Sensor, Traction Motor **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **529 0.5**  **1 1**  0.0200 **$6.07 $41.48**  **$16.39 $16.39**  **$0.12 $0.04**  **$0.03 $0.19**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.19 $0.19**  **$0.12**
6 H Wire Guide Housing, Speed Sensor, Traction Motor **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **257 0.5**  **1 1**  0.0470 **$6.07 $41.48**  **$16.39 $16.39**  **$0.29 $0.08**  **$0.06 $0.43**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.43 $0.43**  **$0.29**
7 H Plate , Asm., Traction Motor **1** Coat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Conformal Coat, UV Cure **103 0.5**  **1 1**  0.000 **$6.07 $36.21**  **$28.33 $28.33**  **$0.00 $0.18**  **$0.28 $0.45**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.45 $0.45**  **$0.00**
8 **1** Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, HC, Base **103 0.25**  **1 1**  0.000 **$0.00 $37.35**  **$45.00 $45.00**  **$0.00 $0.09**  **$0.44 $0.53**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.53 $0.53**  **$0.00**
9 **8** Stamping T1 Assembly, Mark-up Applied @ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS **24000 2**  **4 1**  0.163 **$0.75 $42.73**  **$24.60 $98.40**  **$0.12 $0.00**  **$0.00 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $1.04**  **$0.98**
10 **1** Rotor Stacking T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Cut/Punch/Forming Operator Elec. Assembly, MC, Base **294 0**  **4 1**  0.000 **$0.00 $42.73**  **$30.00 $120.00**  **$0.00 $0.00**  **$0.41 $0.41**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.41 $0.41**  **$0.00** 10 **1** Rotor Stacking @ Bottom. Not Applicable Cut/Punch/Forming Operator Elec. Assembly, MC, Base **294 0**  **4 1**  0.000 **$0.00 $42.73**  **$30.00 $120.00**  **$0.00 $0.00**  **$0.41 $0.41**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.41 $0.41**  **$0.00**
11 **1** Winding T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, HC, Base **136 4**  **4 1**  0.000 **$0.00 $37.35**  **$45.00 $180.00**  **$0.00 $1.10**  **$1.33 $2.42**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$2.42 $2.42**  **$0.00**
12 **1** Solder T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Elec. Assembly, LC **369 2**  **2 1**  0.000 **$0.00 $44.96**  **$100.00 $200.00**  **$0.00 $0.24**  **$0.54 $0.79**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.79 $0.79**  **$0.00**
13 **1** Potting T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, LC **277 0.5**  **1 1**  0.000 **$0.00 $37.35**  **$100.00 $100.00**  **$0.00 $0.07**  **$0.36 $0.43**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.43 $0.43**  **$0.00**
14 **1** Vibration Weld T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Elec. Assembly, LC **327 0.5**  **1 1**  0.000 **$0.00 $44.96**  **$100.00 $100.00**  **$0.00 $0.07**  **$0.31 $0.37**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.37 $0.37**  **$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**



### 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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Speed Sensor Asm., Traction Motor**  

## Part Number: **021104-N0502-02** 

## 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 **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Parallel HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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** 

### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**


### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 
1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub
Assembly. 2 H Potting Compound, Speed Sensor **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01** 3 H Terminal Inserts, Speed **6** S **$0.00** $0.02 **$0.00 $0.12**  **$0.12** 4 H Copper Wire, Speed Sensor, Gen **3** S **$0.00** $0.44 **$0.00 $1.32**  **$1.32** 5 H Bolt, Speed Sensor, Traction Motor **3** Mounting Hardware into Trans S **$0.00** $0.04 **$0.00 $0.12**  **$0.12** 6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### Assembly. "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to



### 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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Speed Sensor Asm., Traction Motor**  

## Part Number: **021104-N0502-02** 

## 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 **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Parallel HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 Material**  **$3.06**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$8.80 T1 or OEM Total Manufacturing Cost:**  **$3.06 $1.93**  **$3.81 $8.80**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $8.80** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$0.04 $0.57**  **$0.53 $0.22**  **$1.36 Base Cost Impact to Vehicle:**  **$3.06 $1.93**  **$3.81 $8.80**  **$0.04 $0.57**  **$0.53 $0.22**  **$1.36 $10.17**  **$0 $0**  **Packaging Cost: $0.10**  **Net Cost Impact to Vehicle: $10.27** 

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 
**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### 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. 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: 4 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



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

H Lower Cover, Speed Sensor, Traction Motor H Upper Cover, Speed Sensor, Traction Motor H Wire Guide Housing, Speed Sensor, Traction Motor H Plate , Asm., Traction Motor **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $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**  **$0.04 $0.03**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  One Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6.8 1 1 6.8 **1.0 1.0**  **$0.04 $0.03**  **$0.19 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  One Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6.8 1 1 6.8 **1.0 1.0**  **$0.08 $0.06**  **$0.43 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  One Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14.014 1 1 14.014 **1.0 1.0**  **$0.18 $0.28**  **$0.45 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Add conformal coating, drip varnish **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 35 1 1 35 **1.0 1.0**  **$0.09 $0.44**  **$0.53 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  1 person 2 station 30 sec test **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 35 1 1 35 **1.0 1.0**  **$0.03 $0.03**  **$1.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Progressive stamping die in-line with automatic rotor disc stacking equipment. **5 2**  **10 100**  **47 4700**  **766 4.70**  **85% 901**  **4.00** 0.6 2 1 0.6 **1.0 4.0**  **$0.00 $0.41**  **$0.41 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Rotor stacking equipment, direct feed from stamping press, orientate, stack and press into place **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 214 1 1 49 **1.0 4.0**  Rotor stacking equipment, direct feed from stamping press, orientate, stack and press into place **$1.10 $1.33**  **$2.42 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  4 station 4 person winding asm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 106 1 1 106 **1.0 4.0**  **$0.24 $0.54**  **$0.79 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  2 station 2 person six welds per asm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 39 1 1 19.5 **1.0 2.0**  **$0.07 $0.36**  **$0.43 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Apply potting compound **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0**  **$0.07 $0.31**  **$0.37 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Vibration weld **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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: 5 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00** H Potting Compound, Speed Sensor H Terminal Inserts, Speed H Copper Wire, Speed Sensor, Gen H Bolt, Speed Sensor, Traction Motor **$0.01 $0.12**  **$1.32 $0.12**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $1.93**  **$3.81 $8.80**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 2**  **$8.80** 

### 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: 7 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



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

H Lower Cover, Speed Sensor, Traction Motor H Upper Cover, Speed Sensor, Traction Motor H Wire Guide Housing, Speed Sensor, Traction Motor H Plate , Asm., Traction Motor **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

**#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **529 6.80**  0.50
**529 6.80**  0.50
**257 14.01**  0.50
**103 35.00**  0.50
**103 35.00**  0.25
**24000 0.15**  2.00
**294 12.24** 
- **136 26.50**  4.00
**369 9.75**  2.00
**277 13.00**  0.50
**327 11.00**  0.50 **#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: 8 of 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

H Potting Compound, Speed Sensor H Terminal Inserts, Speed H Copper Wire, Speed Sensor, Gen H Bolt, Speed Sensor, Traction Motor



### 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 9 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 22**  

## Part Number: **021104-N0502-03A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574 **10 North America**  **North America FOB Ship Point**  **47 450,000**  **1 450,000** 

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### B 

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

1 Harness, PCB Curr Sensor 22: **1** Electrical Test & Inspect T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **240 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.08**  **$0.06 $0.14**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.14 $0.14**  **$0.00**

2 Harness, PCB Curr Sensor 22: 8 Cavity

Connector; 8 Cavity Connector TPA; 7 Cavity Connector **1** Asm Terminals in 8 Cavity Conn & fasten w/ TPA and asm Terminals in 7 Cavity Conn T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **120 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.32**  **$0.13 $0.45**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.45 $0.45**  **$0.00** Connector Terminals in 7 Cavity Conn

3 Harness, PCB Curr Sensor 22: 1.0mm

Terminals; 0.64mm Terminals **1** Asm 1.0mm Terminals & Crimp and 0.64mm Terminals & Crimp T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **116 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.33**  **$0.13 $0.46**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.46 $0.46**  **$0.00**

4 Harness, PCB Curr Sensor 22: Fabric Sleeve;

Sensor Asm Closeout **1** Asm Fabric Sleeve & Assemble / Glue Sensor Asm Closeout T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **157 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.25**  **$0.10 $0.34**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.34 $0.34**  **$0.00**

5 Harness, PCB Curr Sensor 22: Wires **1** Cut Wire Length & End Prep T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **360 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.04 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
5 H Cover, Current Sensor 22 **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PBT GF-30 FR Mold/Cast/Sinter Operator Inject. Mold, SS **7200 0.5**  **1 1**  0.0331 **$2.06 $41.48**  **$16.39 $16.39**  **$0.07 $0.00**  **$0.00 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.07** 

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

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 22**  

## Part Number: **021104-N0502-03A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

6 H Base Curr Sensor,Material **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PBT GF-30 FR Mold/Cast/Sinter Operator Inject. Mold, SS **3015 0.5**  **1 1**  0.2430 **$2.06 $41.48**  **$16.39 $16.39**  **$0.50 $0.01**  **$0.01 $0.51**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.51 $0.51**  **$0.50**
7 H Anti-crush sleeve, Curr **2** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **257 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.04**  **$0.04 $0.08**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.08 $0.16**  **$0.00**
8 **2** Machine T1 Assembly, Mark-up Applied @ Bottom. Si-Brass-87500, Bar CNC Operator CNC Turning, SS, BF, DA **277 1**  **2 1**  0.020 **$2.11 $36.98**  **$20.48 $40.96**  **$0.04 $0.13**  **$0.15 $0.32**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.32 $0.65**  **$0.08**
9 H Laminate, Curr Sensor **17** Roll Form/Cut T1 Assembly, Mark-up Applied @ Bottom. Laminate, Material Cut/Punch/Forming Operator Stamp/Form, Terminals **275 0.5**  **1 1**  0.005 **$9.68 $42.73**  **$15.50 $15.50**  **$0.0484 $0.08**  **$0.06 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $3.10**  **$0.82**
10 H Laminate, Curr Sensor **17** Roll Form/Cut T1 Assembly, Mark-up Applied @ Bottom. Laminate, Material Cut/Punch/Forming Operator Stamp/Form, Terminals **275 0.5**  **1 1**  0.005 **$9.68 $42.73**  **$15.50 $15.50**  **$0.05 $0.08**  **$0.06 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $3.10**  **$0.82**
11 H Laminate, Curr Sensor **17** Roll Form/Cut T1 Assembly, Mark-up Applied @ Bottom. Laminate, Material Cut/Punch/Forming Operator Stamp/Form, Terminals **275 0.5**  **1 1**  0.005 **$9.68 $42.73**  **$15.50 $15.50**  **$0.05 $0.08**  **$0.06 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $3.10**  **$0.82**
12 H Base Curr Sensor **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **400 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.10**  **$0.04 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.00**
13 H Base Asm,Curr Sensor **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **751 5**  **5 1**  0.000 **$0.00 $38.55**  **$15.00 $75.00**  **$0.00 $0.26**  **$0.10 $0.36**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.36 $0.36**  **$0.00**
14 H Current Sensor, 22 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **100 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.39**  **$0.15 $0.54**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.54 $0.54**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



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

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 22**  

## Part Number: **021104-N0502-03A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**


### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item**  1 22ga wire: **7.875** S **$0.00** $0.01 **$0.00 $0.12**  **$0.12** 2 Fabric Covering: **0.708** S **$0.00** $0.11 **$0.00 $0.08**  **$0.08** 3 7x1.0mm connector: **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10** 4 1.0mm terminals **7** S **$0.00** $0.08 **$0.00 $0.59**  **$0.59** 5 8x0.64mm connector: **1** S **$0.00** $0.11 **$0.00 $0.11**  **$0.11** 6 0.64mm terminals: **7** S **$0.00** $0.07 **$0.00 $0.49**  **$0.49** 7 Sensor Asm Closeout **2** S **$0.00** $0.03 **$0.00 $0.06**  **$0.06** 8 8 Cavity Conn TPA **2** S **$0.00** $0.05 **$0.00 $0.09**  **$0.09** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 H Label, Curr Sensor **1** S **$0.00** $0.050 **$0.00 $0.05**  **$0.05** 11 H Screw, PCB **2** S **$0.00** $0.04 **$0.00 $0.08**  **$0.08** 12 H Bolt, Current Sensor **2** S **$0.00** $0.04 **$0.00 $0.08**  **$0.08** 13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub
Assembly. "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub
- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark
- up Calculations. "Alpha
- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 Material**  **$4.96** 

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

### Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 22**  

## Part Number: **021104-N0502-03A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$15.05 T1 or OEM Total Manufacturing Cost:**  **$4.96 $6.09**  **$4.01 $15.05**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $15.05** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$0.08 $0.98**  **$0.90 $0.38**  **$2.33 Base Cost Impact to Vehicle:**  **$4.96 $6.09**  **$4.01 $15.05**  **$0.08 $0.98**  **$0.90 $0.38**  **$2.33 $17.38**  **$0 $0**  **Packaging Cost: $0.05**  **Net Cost Impact to Vehicle: $17.43**  **3 1**  

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

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 
**Packaging Cost per Piece**  **Tier Pad Price Per**  **Tier Pads**

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnables Last 5 Years Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet
- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



## Purchase Part - High Impact Item (Full Cost Mapping)
Harness, PCB Curr Sensor 22: Harness, PCB Curr Sensor 22: 8 Cavity Connector; 8 Cavity Connector TPA; 7 Cavity Connector **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.08 $0.06**  **$0.14 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Electrical Test & Inspect; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 15 1 1 15 **1.0 1.0** 
**$0.32 $0.13**  **$0.45 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Asm Terminals in 8 Cavity Connector & fasten w/ TPA and 7 Cavity Connector; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 30 1 1 30 **1.0 1.0**  Connector Harness, PCB Curr Sensor 22: 1.0mm Terminals; 0.64mm Terminals Harness, PCB Curr Sensor 22: Fabric Sleeve; Sensor Asm Closeout Harness, PCB Curr Sensor 22: Wires H Cover, Current Sensor 22 **$0.33 $0.13**  **$0.46 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Asm 1.0mm Terminals (7x) & Crimp and 0.64mm Terminals (7x) & Crimp; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 31 1 1 31 **1.0 1.0** 
**$0.25 $0.10**  **$0.34 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Asm Fabric Sleeve & Asm / Glue Sensor Closeout; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 23 1 1 23 **1.0 1.0** 
**$0.05 $0.04**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Cut Wire Length (7x) & End Prep (14x); operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 10 1 1 10 **1.0 1.0**  **$0.00 $0.00**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  10 Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.500 1 10 5.00 **1.0 1.0**  

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

### Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Base Curr Sensor,Material
H Anti-crush sleeve, Curr

H Laminate, Curr Sensor H Laminate, Curr Sensor H Laminate, Curr Sensor 

### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.01 $0.01**  **$0.51 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  10 Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.194 1 10 11.94 **1.0 1.0**  **$0.07 $0.08**  **$0.16 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Batch Wash **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 14 1 1 14 **1.0 1.0**  **$0.27 $0.30**  **$0.65 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 26 7 1 26 **1.0 2.0**  **$1.32 $0.96**  **$3.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Roll Form **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 13.1 1 1 13.1 **1.0 1.0**  **$1.32 $0.96**  **$3.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Roll Form **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 13.1 1 1 13.1 **1.0 1.0**  **$1.32 $0.96**  **$3.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Roll Form **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 13.1 1 1 13.1 **1.0 1.0**  H Base Curr Sensor H Base Asm,Curr Sensor
H Current Sensor, 22



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.10 $0.04**  **$0.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Place inserts into mold for overmold processing **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9 2 1 9 **1.0 1.0**  **$0.26 $0.10**  **$0.36 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Place laminated material (3) into base and glue. Apply label **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 23.96 2 1 23.96 **1.0 5.0**  **$0.39 $0.15**  **$0.54 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Attach harness to PCB and set in base. Snap on cover **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 36 2 1 36 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

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

### Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database)
22ga wire: Fabric Covering: 7x1.0mm connector: 1.0mm terminals 8x0.64mm connector: 0.64mm terminals: Sensor Asm Closeout 8 Cavity Conn TPA H Label, Curr Sensor H Screw, PCB H Bolt, Current Sensor **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.12 $0.08**  **$0.10 $0.59**  **$0.11 $0.49**  **$0.06 $0.09**  **$0.00 $0.05**  **$0.08 $0.08**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $6.09**  **$4.01 $15.05**  **$0.00 $0.00**  **$0.00 $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: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$15.05 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: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



## Purchase Part - High Impact Item (Full Cost Mapping)
Harness, PCB Curr Sensor 22: Harness, PCB Curr Sensor 22: 8 Cavity Connector; 8 Cavity Connector TPA; 7 Cavity Connector **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

**240 15.00**  0.50

**120 30.00**  1.00 Connector Harness, PCB Curr Sensor 22: 1.0mm Terminals; 0.64mm Terminals Harness, PCB Curr Sensor 22: Fabric Sleeve; Sensor Asm Closeout Harness, PCB Curr Sensor 22: Wires H Cover, Current Sensor 22 **116 31.00**  1.00

**157 23.00**  1.00

**360 10.00**  0.50
**7200 0.50**  0.50 

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

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Base Curr Sensor,Material
H Anti-crush sleeve, Curr

H Laminate, Curr Sensor H Laminate, Curr Sensor H Laminate, Curr Sensor**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** 

**3015 1.19**  0.50
**257 14.00**  0.25
**277 13.00**  1.00
**275 13.10**  0.50
**275 13.10**  0.50
**275 13.10**  0.50 H Base Curr Sensor H Base Asm,Curr Sensor
H Current Sensor, 22



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **400 9.00**  1.00
**751 4.79**  5.00
**100 36.00**  1.00 **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

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

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

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database)
22ga wire: Fabric Covering: 7x1.0mm connector: 1.0mm terminals 8x0.64mm connector: 0.64mm terminals: Sensor Asm Closeout 8 Cavity Conn TPA H Label, Curr Sensor H Screw, PCB H Bolt, Current Sensor **#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: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB - Current Sensor 22**  

## Part Number: **021104-N0502-03B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### B 

## Purchase Part - High Impact Item (Full Cost Mapping)
1 **0 #####**  **0 2**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 H Board, Control Unit, Generator **1** PCB Functional Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly EOL Func.Test, High Content **185 2**  **2 1**  0.000 **$0.00 $29.83**  **$42.27 $84.54**  **$0.00 $0.32**  **$0.46 $0.78**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.78 $0.78**  **$0.00**
3 **1** Elec depanel Router T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router **245 1**  **1 1**  0.000 **$0.00 $29.83**  **$24.38 $24.38**  **$0.00 $0.12**  **$0.10 $0.22**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.22 $0.22**  **$0.00**
4 **1** Conformal Coating T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Conformal Coat, Heat Cure **450 1**  **1 1**  0.000 **$0.00 $29.83**  **$28.33 $28.33**  **$0.00 $0.07**  **$0.06 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.00**
5 **1** Elec Thru Hole Auto Place T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Thru Hole, Auto **327 1**  **4 1**  0.000 **$0.00 $29.83**  **$62.59 $250.36**  **$0.00 $0.09**  **$0.76 $0.86**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.86 $0.86**  **$0.00**
6 **1** Top Side Processing T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, Medium Content **361 1**  **1 1**  0.000 **$0.00 $29.83**  **$218.25 $218.25**  **$0.00 $0.08**  **$0.60 $0.69**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.69 $0.69**  **$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**



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

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB - Current Sensor 22**  

## Part Number: **021104-N0502-03B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**


### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item**  1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 2 Transistor PNP med Power **3** KE L S **$0.00** $0.29 **$0.00 $0.87**  **$0.87** 3 SMD Diode **9** 64K, 75G S **$0.00** $0.01 **$0.00 $0.09**  **$0.09** 4 Capacitors mixed **9** S **$0.00** $0.01 **$0.00 $0.09**  **$0.09** 5 Resistors mixed **59** S **$0.00** $0.01 **$0.00 $0.59**  **$0.59** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub
Assembly. "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub
- Assembly. In addition component material cost is 5 Resistors mixed **59** S **$0.00** $0.01 **$0.00 $0.59**  **$0.59** 6 H PCB Traction Conformal Coating, Top **1** S **$0.00** $0.20 **$0.00 $0.20**  **$0.20** 7 H PCB, Current Sensor FR4 **1** S **$0.00** $0.51 **$0.00 $0.51**  **$0.51** 8 9 8D Sensor Magnetic 4pin **3** S **$0.00** $0.95 **$0.00 $2.85**  **$2.85** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### T1 or OEM for Final or Sub
- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark
- up Calculations.



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

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB - Current Sensor 22**  

## Part Number: **021104-N0502-03B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 31 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 32 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 33 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 34 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 35 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 36 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 37 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 38 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 39 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 40 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 41 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 42 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 43 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 44 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 45 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 46 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 47 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 48 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 49 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 50 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 51 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 52 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 53 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 54 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 55 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 56 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 57 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 58 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 59 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 60 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 61 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 62 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 63 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 64 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 65 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 66 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 67 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 68 **0 $0.00**  $0.00 **$0.00 $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: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB - Current Sensor 22**  

## Part Number: **021104-N0502-03B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

69 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 70 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 71 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 72 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 Material**  **$5.20**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$7.87 T1 or OEM Total Manufacturing Cost:**  **$5.20 $0.68**  **$1.99 $7.87**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $7.87** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **3 1**  

### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$0.04 $0.51**  **$0.47 $0.20**  **$1.22 Base Cost Impact to Vehicle:**  **$5.20 $0.68**  **$1.99 $7.87**  **$0.04 $0.51**  **$0.47 $0.20**  **$1.22 $9.10**  **$0 $0**  **Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $9.10** 

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 
**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnables Last 5 Years Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet
- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



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

H Board, Control Unit, Generator **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$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**  **$0.32 $0.46**  **$0.78 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Elec Functional Test Station **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 39 1 1 39 **1.0 2.0**  **$0.12 $0.10**  **$0.22 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Electrical K&S Depaneler router three inches/second **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14.7 1 1 14.7 **1.0 1.0**  **$0.07 $0.06**  **$0.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Elec PVA PVA650SMT **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 8 1 1 8 **1.0 1.0**  **$0.09 $0.76**  **$0.86 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Elec Manual Station Thru Hole **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 44 3 1 44 **1.0 4.0**  **$0.08 $0.60**  **$0.69 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Chip Loading - Elec SMD Universal GC-12 for stanard size/shape chips. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9.97 1 1 9.97 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



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



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

Transistor PNP med Power SMD Diode Capacitors mixed Resistors mixed **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.87**  **$0.09 $0.09**  **$0.59** Resistors mixed H PCB Traction Conformal Coating, Top H PCB, Current Sensor FR4 9 8D Sensor Magnetic 4pin **$0.20 $0.51**  **$2.85 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  

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

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.00**  **$0.00 $0.00**  **Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $0.68**  **$1.99 $7.87**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $7.87**  **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: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



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

H Board, Control Unit, Generator **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

**#DIV/0! #DIV/0!** 
- **185 19.50**  2.00
**245 14.70**  1.00
**450 8.00**  1.00
**327 11.00**  1.00
**361 9.97**  1.00 **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-


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

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



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



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

Transistor PNP med Power SMD Diode Capacitors mixed Resistors mixed **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

Resistors mixed H PCB Traction Conformal Coating, Top H PCB, Current Sensor FR4 9 8D Sensor Magnetic 4pin



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

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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

### Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 75**  

## Part Number: **021104-N0502-04A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574 **10 North America**  **North America FOB Ship Point**  **47 450,000**  **1 450,000** 

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### B 

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

1 Harness, PCB Curr Sensor 75: **1** Electrical Test & Inspect T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **240 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.08**  **$0.06 $0.14**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.14 $0.14**  **$0.00**

2 Harness, PCB Curr Sensor 75: 8 Cavity

Connector; 8 Cavity Connector TPA; 7 Cavity Connector **1** Asm Terminals in 8 Cavity Conn & fasten w/ TPA and asm Terminals in 7 Cavity Conn T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **120 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.32**  **$0.13 $0.45**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.45 $0.45**  **$0.00** Connector Terminals in 7 Cavity Conn

3 Harness, PCB Curr Sensor 75: 1.0mm

Terminals; 0.64mm Terminals **1** Asm 1.0mm Terminals & Crimp and 0.64mm Terminals & Crimp T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **116 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.33**  **$0.13 $0.46**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.46 $0.46**  **$0.00**

4 Harness, PCB Curr Sensor 75: Fabric Sleeve;

Sensor Asm Closeout **1** Asm Fabric Sleeve & Assemble / Glue Sensor Asm Closeout T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **157 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.25**  **$0.10 $0.34**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.34 $0.34**  **$0.00**

5 Harness, PCB Curr Sensor 75: Wires **1** Cut Wire Length & End Prep T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base **360 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.04 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
6 **0** T1 Assembly, Mark-up Applied @ Bottom. **##### 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% #N/A**  **#N/A $0.00**  **$0.00** 

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

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 75**  

## Part Number: **021104-N0502-04A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

6 H Cover, Current Sensor 75 **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PBT GF-30 FR Mold/Cast/Sinter Operator Inject. Mold, SS **7200 0.5**  **1 1**  0.0331 **$2.06 $41.48**  **$16.39 $16.39**  **$0.07 $0.00**  **$0.00 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.07**
7 H Base Curr Sensor,Material **1** Mold T1 Assembly, Mark-up Applied @ Bottom. PBT GF-30 FR Mold/Cast/Sinter Operator Inject. Mold, SS **3015 0.5**  **1 1**  0.2430 **$2.06 $41.48**  **$16.39 $16.39**  **$0.50 $0.01**  **$0.01 $0.51**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.51 $0.51**  **$0.50**
8 H Anti-crush sleeve, Curr **2** Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC **257 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.04**  **$0.04 $0.08**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.08 $0.16**  **$0.00**
9 **2** Machine T1 Assembly, Mark-up Applied @ Bottom. Si-Brass-87500, Bar CNC Operator CNC Turning, SS, BF, DA **277 1**  **2 1**  0.020 **$2.11 $36.98**  **$20.48 $40.96**  **$0.04 $0.13**  **$0.15 $0.32**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.32 $0.65**  **$0.08**
10 H Laminate, Curr Sensor **17** Roll Form/Cut T1 Assembly, Mark-up Applied @ Bottom. Laminate, Material Cut/Punch/Forming Operator Stamp/Form, Terminals **275 0.5**  **1 1**  0.005 **$9.68 $42.73**  **$15.50 $15.50**  **$0.0484 $0.08**  **$0.06 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $3.10**  **$0.82**
11 H Laminate, Curr Sensor **17** Roll Form/Cut T1 Assembly, Mark-up Applied @ Bottom. Laminate, Material Cut/Punch/Forming Operator Stamp/Form, Terminals **275 0.5**  **1 1**  0.005 **$9.68 $42.73**  **$15.50 $15.50**  **$0.05 $0.08**  **$0.06 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $3.10**  **$0.82**
12 H Laminate, Curr Sensor **17** Roll Form/Cut T1 Assembly, Mark-up Applied @ Bottom. Laminate, Material Cut/Punch/Forming Operator Stamp/Form, Terminals **275 0.5**  **1 1**  0.005 **$9.68 $42.73**  **$15.50 $15.50**  **$0.05 $0.08**  **$0.06 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $3.10**  **$0.82**
13 H Base Curr Sensor **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **400 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.10**  **$0.04 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.00**
14 H Base Asm,Curr Sensor **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **150 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.26**  **$0.10 $0.36**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.36 $0.36**  **$0.00**
15 H Current Sensor, 75 **1** Assemble T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **100 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.39**  **$0.15 $0.54**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.54 $0.54**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 31 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



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

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 75**  

## Part Number: **021104-N0502-04A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**


### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item**  1 22ga wire: **7.146** S **$0.00** $0.01 **$0.00 $0.11**  **$0.11** 2 Fabric Covering: **0.625** S **$0.00** $0.11 **$0.00 $0.07**  **$0.07** 3 7x1.0mm connector: **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10** 4 1.0mm terminals **7** S **$0.00** $0.08 **$0.00 $0.59**  **$0.59** 5 8x0.64mm connector: **1** S **$0.00** $0.11 **$0.00 $0.11**  **$0.11** 6 0.64mm terminals: **7** S **$0.00** $0.07 **$0.00 $0.49**  **$0.49** 7 Sensor Asm Closeout **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03** 8 8 Cavity Conn TPA **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 H Label, Curr Sensor **1** S **$0.00** $0.050 **$0.00 $0.05**  **$0.05** 11 H Screw, PCB **2** S **$0.00** $0.04 **$0.00 $0.08**  **$0.08** 12 H Bolt, Current Sensor **2** S **$0.00** $0.04 **$0.00 $0.08**  **$0.08** 13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub
Assembly. "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub
- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark
- up Calculations. "Alpha
- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**



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

### Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Current Sensor 75**  

## Part Number: **021104-N0502-04A** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb (DB)**  **Labor Rate**  **$/Hour (DB)**  **Burden Rate**  **$/Hour (DB)**  **Applied Burden**  **Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Material $4.86** 
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$14.96 T1 or OEM Total Manufacturing Cost:**  **$4.86 $6.09**  **$4.01 $14.96**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $14.96** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$0.07 $0.97**  **$0.90 $0.37**  **$2.32 Base Cost Impact to Vehicle:**  **$4.86 $6.09**  **$4.01 $14.96**  **$0.07 $0.97**  **$0.90 $0.37**  **$2.32 $17.27**  **$0 $0**  **Packaging Cost: $0.05** 

**3 1**  

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

**Net Cost Impact to Vehicle: $17.32** 

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 
**Packaging Cost per Piece**  **Tier Pad Price Per**  **Tier Pads**

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnables Last 5 Years Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet
- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



## Purchase Part - High Impact Item (Full Cost Mapping)
Harness, PCB Curr Sensor 75: Harness, PCB Curr Sensor 75: 8 Cavity Connector; 8 Cavity Connector TPA; 7 Cavity Connector **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.08 $0.06**  **$0.14 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Electrical Test & Inspect; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 15 1 1 15 **1.0 1.0** 
**$0.32 $0.13**  **$0.45 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Asm Terminals in 8 Cavity Connector & fasten w/ TPA and 7 Cavity Connector; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 30 1 1 30 **1.0 1.0**  Connector Harness, PCB Curr Sensor 75: 1.0mm Terminals; 0.64mm Terminals Harness, PCB Curr Sensor 75: Fabric Sleeve; Sensor Asm Closeout Harness, PCB Curr Sensor 75: Wires **$0.33 $0.13**  **$0.46 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Asm 1.0mm Terminals (7x) & Crimp and 0.64mm Terminals (7x) & Crimp; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 31 1 1 31 **1.0 1.0** 
**$0.25 $0.10**  **$0.34 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Asm Fabric Sleeve & Asm / Glue Sensor Closeout; operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 23 1 1 23 **1.0 1.0** 
**$0.05 $0.04**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Cut Wire Length (7x) & End Prep (14x); operator load/unload & cycle **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 10 1 1 10 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

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

### Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Cover, Current Sensor 75 H Base Curr Sensor,Material
H Anti-crush sleeve, Curr

H Laminate, Curr Sensor H Laminate, Curr Sensor 

### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  10 Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.500 1 10 5.00 **1.0 1.0**  **$0.01 $0.01**  **$0.51 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  10 Cavity Mold, 55 -150 ton inject mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.194 1 10 11.94 **1.0 1.0**  **$0.07 $0.08**  **$0.16 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Batch Wash **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 14 1 1 14 **1.0 1.0**  **$0.27 $0.30**  **$0.65 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 26 7 1 26 **1.0 2.0**  **$1.32 $0.96**  **$3.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Roll Form **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 13.1 1 1 13.1 **1.0 1.0**  **$1.32 $0.96**  **$3.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Roll Form **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 13.1 1 1 13.1 **1.0 1.0**  H Laminate, Curr Sensor H Base Curr Sensor H Base Asm,Curr Sensor
H Current Sensor, 75



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$1.32 $0.96**  **$3.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Roll Form **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 13.1 1 1 13.1 **1.0 1.0**  **$0.10 $0.04**  **$0.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Place inserts into mold for overmold processing **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9 2 1 9 **1.0 1.0**  **$0.26 $0.10**  **$0.36 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Place laminated material (3) into base and glue. Apply label **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 24 2 1 23.96 **1.0 1.0**  **$0.39 $0.15**  **$0.54 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Attach harness to PCB and set in base. Snap on cover **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 36 2 1 36 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

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

### Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database)
22ga wire: Fabric Covering: 7x1.0mm connector: 1.0mm terminals 8x0.64mm connector: 0.64mm terminals: Sensor Asm Closeout 8 Cavity Conn TPA H Label, Curr Sensor H Screw, PCB H Bolt, Current Sensor **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.11 $0.07**  **$0.10 $0.59**  **$0.11 $0.49**  **$0.03 $0.05**  **$0.00 $0.05**  **$0.08 $0.08**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 


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

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $6.09**  **$4.01 $14.96**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $14.96**  **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: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



## Purchase Part - High Impact Item (Full Cost Mapping)
Harness, PCB Curr Sensor 75: Harness, PCB Curr Sensor 75: 8 Cavity Connector; 8 Cavity Connector TPA; 7 Cavity Connector **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

**240 15.00**  0.50

**120 30.00**  1.00 Connector Harness, PCB Curr Sensor 75: 1.0mm Terminals; 0.64mm Terminals Harness, PCB Curr Sensor 75: Fabric Sleeve; Sensor Asm Closeout Harness, PCB Curr Sensor 75: Wires **116 31.00**  1.00

**157 23.00**  1.00

**360 10.00**  0.50 **#DIV/0! #DIV/0!** 
- 

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

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Cover, Current Sensor 75 H Base Curr Sensor,Material
H Anti-crush sleeve, Curr

H Laminate, Curr Sensor H Laminate, Curr Sensor**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** 

**7200 0.50**  0.50
**3015 1.19**  0.50
**257 14.00**  0.25
**277 13.00**  1.00
**275 13.10**  0.50
**275 13.10**  0.50 H Laminate, Curr Sensor H Base Curr Sensor H Base Asm,Curr Sensor
H Current Sensor, 75



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **275 13.10**  0.50
**400 9.00**  1.00
**150 23.96**  1.00
**100 36.00**  1.00 **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

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

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

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database)
22ga wire: Fabric Covering: 7x1.0mm connector: 1.0mm terminals 8x0.64mm connector: 0.64mm terminals: Sensor Asm Closeout 8 Cavity Conn TPA H Label, Curr Sensor H Screw, PCB H Bolt, Current Sensor **#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: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB Current Sensor 75**  

## Part Number: **021104-N0502-04B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574 **10 North America**  **North America FOB Ship Point**  **47 450,000**  **1 450,000** 

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### B 

## Purchase Part - High Impact Item (Full Cost Mapping)
1 **0 #####**  **0 2**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 H Board, Control Unit, Generator **1** PCB Functional Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly EOL Func.Test, High Content **185 2**  **2 1**  0.000 **$0.00 $29.83**  **$42.27 $84.54**  **$0.00 $0.32**  **$0.46 $0.78**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.78 $0.78**  **$0.00**
3 **1** Elec depanel Router T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router **245 1**  **1 1**  0.000 **$0.00 $29.83**  **$24.38 $24.38**  **$0.00 $0.12**  **$0.10 $0.22**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.22 $0.22**  **$0.00**
4 **1** Conformal Coating T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Conformal Coat, Heat Cure **450 1**  **1 1**  0.000 **$0.00 $29.83**  **$28.33 $28.33**  **$0.00 $0.07**  **$0.06 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $0.13**  **$0.00**
5 **1** Elec Thru Hole Auto Place T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Thru Hole, Auto **327 1**  **4 1**  0.000 **$0.00 $29.83**  **$62.59 $250.36**  **$0.00 $0.09**  **$0.76 $0.86**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.86 $0.86**  **$0.00**
6 **1** Top Side Processing T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, Medium Content **361 1**  **1 1**  0.000 **$0.00 $29.83**  **$218.25 $218.25**  **$0.00 $0.08**  **$0.60 $0.69**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.69 $0.69**  **$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**



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

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB Current Sensor 75**  

## Part Number: **021104-N0502-04B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**


### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item**  1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 2 Transistor PNP med Power **3** KE L S **$0.00** $0.29 **$0.00 $0.87**  **$0.87** 3 SMD Diode **9** 64K, 75G S **$0.00** $0.01 **$0.00 $0.09**  **$0.09** 4 Capacitors mixed **9** S **$0.00** $0.01 **$0.00 $0.09**  **$0.09** 5 Resistors mixed **59** S **$0.00** $0.01 **$0.00 $0.59**  **$0.59** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub
Assembly. "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub
- Assembly. In addition component material cost is 5 Resistors mixed **59** S **$0.00** $0.01 **$0.00 $0.59**  **$0.59** 6 H PCB Traction Conformal Coating, Top **1** S **$0.00** $0.20 **$0.00 $0.20**  **$0.20** 7 H PCB, Current Sensor FR4 **1** S **$0.00** $0.51 **$0.00 $0.51**  **$0.51** 8 9 8D Sensor Magnetic 4pin **3** S **$0.00** $0.95 **$0.00 $2.85**  **$2.85** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### T1 or OEM for Final or Sub
- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark
- up Calculations.



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

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB Current Sensor 75**  

## Part Number: **021104-N0502-04B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 31 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 32 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 33 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 34 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 35 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 36 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 37 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 38 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 39 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 40 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 41 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 42 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 43 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 44 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 45 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 46 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 47 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 48 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 49 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 50 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 51 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 52 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 53 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 54 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 55 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 56 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 57 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 58 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 59 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 60 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 61 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 62 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 63 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 64 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 65 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 66 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 67 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 68 **0 $0.00**  $0.00 **$0.00 $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: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H PCB Current Sensor 75**  

## Part Number: **021104-N0502-04B** 

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

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000**

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

69 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 70 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 71 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 72 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 Material**  **$5.20**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$7.87 T1 or OEM Total Manufacturing Cost:**  **$5.20 $0.68**  **$1.99 $7.87**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $7.87** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **3 1**  

### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 
----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$0.04 $0.51**  **$0.47 $0.20**  **$1.22 Base Cost Impact to Vehicle:**  **$5.20 $0.68**  **$1.99 $7.87**  **$0.04 $0.51**  **$0.47 $0.20**  **$1.22 $9.10**  **$0 $0**  **Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $9.10** 

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 
**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnables Last 5 Years Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet
- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



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

H Board, Control Unit, Generator **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$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**  **$0.32 $0.46**  **$0.78 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Elec Functional Test Station **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 39 1 1 39 **1.0 2.0**  **$0.12 $0.10**  **$0.22 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Electrical K&S Depaneler router three inches/second **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14.7 1 1 14.7 **1.0 1.0**  **$0.07 $0.06**  **$0.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Elec PVA PVA650SMT **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 8.0 1 1 8.0 **1.0 1.0**  **$0.09 $0.76**  **$0.86 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Elec Manual Station Thru Hole **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 44.0 3 1 44.0 **1.0 4.0**  **$0.08 $0.60**  **$0.69 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Chip Loading - Elec SMD Universal GC-12 for stanard size/shape chips. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9.97 1 1 9.97 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 



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

Transistor PNP med Power SMD Diode Capacitors mixed Resistors mixed **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.00 $0.87**  **$0.09 $0.09**  **$0.59** Resistors mixed H PCB Traction Conformal Coating, Top H PCB, Current Sensor FR4 9 8D Sensor Magnetic 4pin **$0.20 $0.51**  **$2.85 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  

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

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $0.68**  **$1.99 $7.87**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $7.87**  **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: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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



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

H Board, Control Unit, Generator **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

**#DIV/0! #DIV/0!** 
- **185 19.50**  2.00
**245 14.70**  1.00
**450 8.00**  1.00
**327 11.00**  1.00
**361 9.97**  1.00 **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-


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

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



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



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

Transistor PNP med Power SMD Diode Capacitors mixed Resistors mixed **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

Resistors mixed H PCB Traction Conformal Coating, Top H PCB, Current Sensor FR4 9 8D Sensor Magnetic 4pin



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

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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

### Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



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