Material Labor Burden End Item Scrap SG&A Profit ED&TR&D



## 02 **TRANSMISSION SYSTEM**

1 **01 EXTERNAL COMPONENTS:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

2 **02 CASE(S):**  **5.50 $**  **1.19**

**$ 14.17** 

**$ 20.85** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 20.85** 

**$**

3 **03 GEAR TRAIN:**  **20.23 $**  **5.58**

**$ 38.23** 

**$ 64.04** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 64.04** 

**$**

4 **04 INTERNAL CLUTCHES:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

5 **05 LAUNCH CLUTCHES:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

6 **06 OIL PUM**  **P & FILTER:**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

7 **07 MECHANICAL CONTROLS:**  **47.26 $**  **12.23**

**$ 36.26** 

**$ 95.75** 

**$ 0.33** 

**$ 4.50** 

**$ 4.04** 

**$ 1.53** 

**$ 10.40** 

**$**

**-**

**$ 106.15** 

**$**

8 **08 ELECTRICAL CONTROLS: (Combined w/ Mechnical Controls)** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

9 **09 PARK MECHANISM:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

10 **10 MISCELLANEOUS ITEMS:**  **1.82 $**  **2.78**

**$ 2.50** 

**$ 7.10** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 7.10** 

**$**

**74.82 $**  **21.77**

**$ 91.16** 

**$ 187.74** 

**$ 0.33** 

**$ 4.50** 

**$ 4.04** 

**$ 1.53** 

**$ 10.40** 

**$**

**-**

**$ 198.14** 

**$**

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D



## 02 **TRANSMISSION SYSTEM Net**  **Component/ Assembly**  **Cost Impact to OEM**  **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

Sub-Subsystem Description Manufacturing 

### SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY PACKAGE COST INFORMATION 8-Speed Wet DCT** 

**SYSTEM & SUBSYSTEM DESCRIPTION BASE TECHNOLOGY PACKAGE COST INFORMATION**  **6 Speed Wet DCT**ItemSubsystem

Sub-Subsystem Description Manufacturing

**SUBSYSTEM ROLL-UP Net**  **Component/ Assembly**  **Cost Impact to OEM**  **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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



## 02 **TRANSMISSION SYSTEM**

1 **01 EXTERNAL COMPONENTS:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

2 **02 CASE(S):** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

3 **03 GEAR TRAIN:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

4 **04 INTERNAL CLUTCHES:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

5 **05 LAUNCH CLUTCHES:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

6 **06 OIL PUM**  **P & FILTER:**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

7 **07 MECHANICAL CONTROLS:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

8 **08 ELECTRICAL CONTROLS: (Combined w/ Mechnical Controls)** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

9 **09 PARK MECHANISM:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

10 **10 MISCELLANEOUS ITEMS:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D



## 02 **TRANSMISSION SYSTEM**

1 **01 EXTERNAL COMPONENTS:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

2 **02 CASE(S):**  **5.50 $**  **1.19**

**$ 14.17** 

**$ 20.85** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 20.85** 

**$**

3 **03 GEAR TRAIN:**  **20.23 $**  **5.58**

**$ 38.23** 

**$ 64.04** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 64.04** 

**$** 64.04 $

4 **04 INTERNAL CLUTCHES:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

5 **05 LAUNCH CLUTCHES:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

6 **06 OIL PUM**  **P & FILTER:**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

7 **07 MECHANICAL CONTROLS:**  **47.26 $**  **12.23**

**$ 36.26** 

**$ 95.75** 

**$ 0.33** 

**$ 4.50** 

**$ 4.04** 

**$ 1.53** 

**$ 10.40** 

**$**

**-**

**$ 106.15** 

**$**ItemSubsystem

Sub-Subsystem Description **Net Component/**  **Assembly Cost Impact**  **to OEM Total**  **Packaging Cost**  **(Component / Assembly)**  **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  Manufacturing **SUBSYSTEM ROLL-UP**



### SYSTEM & SUBSYSTEM DESCRIPTION **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**

7 **07 MECHANICAL CONTROLS:**  **47.26 $**  **12.23**

**$ 36.26** 

**$ 95.75** 

**$ 0.33** 

**$ 4.50** 

**$ 4.04** 

**$ 1.53** 

**$ 10.40** 

**$**

**-**

**$ 106.15** 

**$**

8 **08 ELECTRICAL CONTROLS: (Combined w/ Mechnical Controls)** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

9 **09 PARK MECHANISM:** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

10 **10 MISCELLANEOUS ITEMS:**  **1.82 $**  **2.78**

**$ 2.50** 

**$ 7.10** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 7.10** 

**$ 74.82**  **$ 21.77** 

**$ 91.16** 

**$ 187.74** 

**$ 0.33** 

**$ 4.50** 

**$ 4.04** 

**$ 1.53** 

**$ 10.40** 

**$**

**-**

**$ 198.14** 

**$ SUBSYSTEM ROLL-UP** 

### Page:1 of 2 

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

198.14 $ 0.0028603

198.14

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D



### 0

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

# 8-Speed DCT Transmission Components (new & modified) Delta

1 **01 Gears**  **18.91 $**  **4.09**

**$ 34.48** 

**$ 57.48** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 57.48** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### a 7th Spd Input Gear 1 Full 1 New component 4.73 $ 1.02

$ 8.62

$ **14.37**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **14.37**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### b 7th Spd Output Gear 1 Full 1 New component 4.73 $ 1.02

$ 8.62

$ **14.37**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **14.37**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### c 8th Spd Input Gear 1 Full 1 New component 4.73 $ 1.02

$ 8.62

$ **14.37**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **14.37**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### d 8th Spd Output Gear 1 Full 1 New component 4.73 $ 1.02

$ 8.62

$ **14.37**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **14.37**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 2 **02 Shafts**  **1.33 $**  **1.49**

**$ 3.75** 

**$ 6.56** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 6.56** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### a Pump Shaft 1 Differential 1 Modified component 0.08 $

-

$

-

$ **0.08**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **0.08**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### b Input Shaft, Inner 1 Differential 1 Modified component 0.12 $ 0.30

$ 0.63

$ **1.04**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.04**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### c Input Shaft, Outer 1 Differential 1 Modified component 0.78 $ 0.30

$ 1.25

$ **2.33**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **2.33**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### d Output Shaft, Upper 1 Differential 1 Modified component 0.12 $ 0.30

$ 0.63

$ **1.04**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.04**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### e Output Shaft, Lowe 1 Differential 1 Modified component 0.12 $ 0.30

$ 0.63

$ **1.04**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.04**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### f Rev erse Shaft 1 Differential 1 Modified component 0.12 $ 0.30

$ 0.63

$ **1.04**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.04**

**$**

**-**

**$**

**-**

**$**

**-**

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

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

### Full, Modification, Differential, or Not Applicable Quote Lev el Scaling

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

**Investment (X1000)**  **Tooling (x1000)**  MarkupAssembly 

### Name/Description Part Number **Total Packaging**  **Cost (Component**  **/ Assembly)** 

## NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

## NEW TECHNOLOGY GENERAL PART INFORMATION: **6 Speed Direct Shift Gearbox (dual clutch) (Max Torque Capacity**  **207 lb*ft)**ItemSubsystem 

## NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** 

## Technology Level: 6

- Speed DCT Transmission vs 8

- Speed DCT Transmission 

## Vehicle Class: Passenger Car, 5 Passengers 

## Study Case#:

f Rev erse Shaft 1 Differential 1 Modified component 0.12 $ 0.30

$ 0.63

$ **1.04**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.04**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 3 **03 Housing / Case**  **5.50 $**  **1.19**

**$ 14.17** 

**$ 20.85** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 20.85** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### Case, Front: 1 Differential 1 Modified component 1.10 $ 0.59

$ 7.08

$ **8.78**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **8.78**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### A Assembly 1 Differential 1 Modified component

- $ 0.30

$ 1.25

$ **1.55**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.55**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### a Machined 1 Differential 1 Modified component 1.10 $ 0.30

$ 5.83

$ **7.23**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **7.23**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### Case, Rear: 1 Differential 1 Modified component 4.40 $ 0.59

$ 7.08

$ **12.08**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **12.08**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### B Assembly 1 Differential 1 Modified component

- $ 0.30

$ 1.25

$ **1.55**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.55**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### b Machined 1 Differential 1 Modified component 4.40 $ 0.30

$ 5.83

$ **10.53**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **10.53**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 4 **04 Mech Controls**  **47.26 $**  **12.23**

**$ 36.26** 

**$ 95.75** 

**$ 0.33** 

**$ 4.50** 

**$ 4.04** 

**$ 1.53** 

**$ 10.40** 

**$**

**-**

**$ 106.15** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### New Components: 41.03 $ 11.30

$ 33.06

$ **85.39**

**$** 0.31

$ 4.18

$ 3.75

$ 1.41

$ **9.66**

**$**

-

$ **95.05**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### a 7th Spd Gear Synchronizer 1 Full 1 New component 3.32 $ 2.12

$ 6.73

$ **12.17**

**$** 0.05

$ 0.66

$ 0.61

$ 0.26

$ **1.58**

**$**

-

$ **13.75**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### b 7th Spd Gear Hub, Shift Collar 1 Full 1 New component 1.21 $ 0.36

$ 0.90

$ **2.47**

**$** 0.01

$ 0.15

$ 0.11

$ 0.01

$ **0.28**

**$**

-

$ **2.74**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### c 7th Spd Gear Shift Hub 1 Full 1 New component 1.01 $ 0.34

$ 0.86

$ **2.21**

**$** 0.01

$ 0.14

$ 0.10

$ 0.01

$ **0.25**

**$**

-

$ **2.46**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### A 7th Spd Gear Shift Fork Assemblies 1 Full 1 New component 5.20 $ 1.22

$ 3.06

$ **9.49**

**$** 0.05

$ 0.61

$ 0.57

$ 0.24

$ **1.46**

**$**

-

$ **10.95**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 1 7th Spd Gear Shift Fork Piston Asm & Cyl. 2 Full 1 New component 0.11 $ 0.58

$ 3.42

$ **4.11**

**$** 0.02

$ 0.27

$ 0.25

$ 0.10

$ **0.64**

**$**

-

$ **4.75**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### B 7th Spd Spool Valv e 1 Full 1 New component 1.41 $ 1.02

$ 1.56

$ **3.99**

**$** 0.02

$ 0.26

$ 0.24

$ 0.10

$ **0.62**

**$**

-

$ **4.61**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### C 7th Spd Solenoid 1 Full 1 New component 8.25 $

-

$

-

$ **8.25**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **8.25**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### d 8th Spd Gear Synchronizer 1 Full 1 New component 3.32 $ 2.12

$ 6.73

$ **12.17**

**$** 0.05

$ 0.66

$ 0.61

$ 0.26

$ **1.58**

**$**

-

$ **13.75**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### e 8th Spd Gear Hub, Shift Collar 1 Full 1 New component 1.21 $ 0.36

$ 0.90

$ **2.47**

**$** 0.01

$ 0.15

$ 0.11

$ 0.01

$ **0.28**

**$**

-

$ **2.74**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### f 8th Spd Gear Shift Hub 1 Full 1 New component 1.01 $ 0.34

$ 0.86

$ **2.21**

**$** 0.01

$ 0.14

$ 0.10

$ 0.01

$ **0.25**

**$**

-

$ **2.46**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### D 8th Spd Gear Shift Fork Assemblies 1 Full 1 New component 5.20 $ 1.22

$ 3.06

$ **9.49**

**$** 0.05

$ 0.61

$ 0.57

$ 0.24

$ **1.46**

**$**

-

$ **10.95**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 3 8th Spd Gear Shift Fork Piston Asm & Cyl. 2 Full 1 New component 0.11 $ 0.58

$ 3.42

$ **4.11**

**$** 0.02

$ 0.27

$ 0.25

$ 0.10

$ **0.64**

**$**

-

$ **4.75**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### E 8th Spd Spool Valv e 1 Full 1 New component 1.41 $ 1.02

$ 1.56

$ **3.99**

**$** 0.02

$ 0.26

$ 0.24

$ 0.10

$ **0.62**

**$**

-

$ **4.61**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### F 8th Spd Solenoid 1 Full 1 New component 8.25 $

-

$

-

$ **8.25**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **8.25**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### Modified Components: 6.24 $ 0.92

$ 3.20

$ **10.36**

**$** 0.02

$ 0.31

$ 0.29

$ 0.12

$ **0.74**

**$**

-

$ **11.10**

**$**

**-**

**$**

**-**

**$**

**-**

**$**


### g Valve Body 1 Differential 1 Modified component 1.10 $ 0.30

$ 1.95

$ **3.34**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **3.34**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 5 Valve Body Asm 1 Differential 1 Modified component

- $ 0.63

$ 1.25

$ **1.88**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.88**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### h Transfer Plate 1 Differential 1 Modified component 1.10 $

-

$

-

$ **1.10**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.10**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### i Valve Body Gasket Plate 1 Differential 1 Modified component 0.16 $

-

$

-

$ **0.16**

**$** 0.00

$ 0.01

$ 0.01

$ 0.00

$ **0.03**

**$**

-

$ **0.19**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### j Valve Body Cover 1 Differential 1 Modified component 1.63 $

-

$

-

$ **1.63**

**$** 0.01

$ 0.11

$ 0.10

$ 0.04

$ **0.25**

**$**

-

$ **1.88**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 6 Oil Pump Distributor 1 Differential 1 Modified component 2.25 $

-

$

-

$ **2.25**

**$** 0.02

$ 0.20

$ 0.18

$ 0.08

$ **0.47**

**$**

-

$ **2.72**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### Pipes, Hoses, Ducting **$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $** 

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 09000064810e70cd.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: D. McDowell (248)373-6000

### Page:2 of 2 

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

198.14 $ 0.0028603

198.14

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D **Net Component/**  **Assembly Cost Impact**  **to OEM System** 

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

### Full, Modification, Differential, or Not Applicable Quote Lev el Scaling

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

**Investment (X1000)**  **Tooling (x1000)**  MarkupAssembly 

### Name/Description Part Number **Total Packaging**  **Cost (Component**  **/ Assembly)** 

## NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

## NEW TECHNOLOGY GENERAL PART INFORMATION: **6 Speed Direct Shift Gearbox (dual clutch) (Max Torque Capacity**  **207 lb*ft)**ItemSubsystem 

## NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** 

## Technology Level: 6

- Speed DCT Transmission vs 8

- Speed DCT Transmission 

## Vehicle Class: Passenger Car, 5 Passengers 

## Study Case#:

75 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 80 **80 Boltings**  **0.02 $** 

**-**

**$**

**-**

**$ 0.02** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.02** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### a Misc Fasteners 1 Commodity 1 New component 0.02 $

-

$

-

$ **0.02**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **0.02**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 85 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 90 **90 Bearing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 99 **99 Miscellaneous**  **1.80 $** 

**-**

**$**

**-**

**$ 1.80** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 1.80** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### a 7th Spd Gear Misc Parts 1 Commodity 1 New component 0.90 $

-

$

-

$ **0.90**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **0.90**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### b 8th Spd Gear Misc Parts 1 Commodity 1 New component 0.90 $

-

$

-

$ **0.90**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **0.90**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 00 **00 Transmission Assembly of Mechanical Control Components** 

**- $**  **2.78**

**$ 2.50** 

**$ 5.28** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 5.28** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### A OEM Transmission Assembly 1 Differential 1 Various

- $ 2.78

$ 2.50

$ **5.28**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **5.28**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**
74.82 $ 21.77

$ 91.16

$ **187.74**

**$** 0.33

$ 4.50

$ 4.04

$ 1.53

$ **10.40**

**$**

-

$ **198.14**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### NA Complete Subsystem Quote

(Yes/No)

09000064810e70cd.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: D. McDowell (248)373-6000

# Technology **Level: 6 Speed DCT vs 8 Speed DCT Transmission**  

# Vehicle Class: **Study Case#:**  **Sy stem Description:**  **6-8 Speed DCT Transmission** 

# Component Description: **Gears** 

# Component Quote Level: 01 Gearing (Input & Output)

**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**

A 

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

1 Input & Output Gears (7&8th Spd) **4** Forge, Trim & Normalize

2 Input & Output Gears (7&8th Spd) **4** CNC Turn & Face (2 Fixturings)
3 Input & Output Gears (7&8th Spd) **4** Hob Gear Teeth
4 Input & Output Gears (7&8th Spd) **4** Chamfer Gear Teeth

5 Input & Output Gears (7&8th Spd) **4** Shave or Roll Gear Teeth

6 Input & Output Gears (7&8th Spd) **4** Press & W eld Synchronizer 

# GENERAL COMPONENT INFORMATION

Input & Output Gears (7&8th Spd)
7 Input & Output Gears (7&8th Spd) **4** Heat Treat
8 Input & Output Gears (7&8th Spd) **4** Grind ID
9 Input & Output Gears (7&8th Spd) **4** Grind Taper on OD
**0**
**0**
**0** 

# B 

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

1 **0**
2 **0**
3 **0**
4 **0**
5 **0** 

# C 

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

1 **0**

2 **0**
3 **0**

4 **0**

5 **0**

# D 

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

1 **0**

2 **0**
3 **0**

4 **0**

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

7 **0**
8 **0**
9 **0**
10 **0**

11 **0**

12 **0**
13 **0**

14 **0**
15 **0**



# 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, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote Cost per 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.)

# 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

# 6 Speed DCT vs 8 Speed DCT Transmission

**6-8 Speed DCT Transmission** 

# Part Number:
01 Gearing (Input & Output)

**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** 



# OEM Transmission Assembly A-Steel-8620, Bar 1-4" Forging Operator Impression/Closed Die Forging, Medium Size **480 2**  **4**

OEM Transmission Assembly Not Applicable CNC Operator CNC Turning, HC, PP, Base **540 1**  **3**

OEM Transmission Assembly Not Applicable CNC Operator Hobbing **480 2**  **6** OEM Transmission Assembly Not Applicable CNC Operator Chamfer Grind **540 1**  **3**

OEM Transmission Assembly Not Applicable CNC Operator Roll Former **540 1**  **3**

OEM Transmission Assembly Not Applicable Forging Operator Press & W eld Station **480 2**  **4**



# GENERAL MANUFACTURING INFORMATION

OEM Transmission Assembly Not Applicable Heat Treat Operator Heat Treat, SMS, LMC **480 2**  **6** OEM Transmission Assembly Not Applicable Forging Operator Grinder **480 1**  **4** OEM Transmission Assembly Not Applicable Forging Operator Grinder **480 1**  **4 #####**  **0 1**  **##### 0**  **1**
**##### 0**  **1**

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

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

**#DIV/0! 0**  **1**
**#DIV/0! 0**  **1**
**#DIV/0! 0**  **1**
**#DIV/0! 0**  **1**

**#DIV/0! 0**  **1**

# Rack/Pallet Investment Amortization:

**Expendable Packaging in Piece Cost: Packaging Cost Total:**  

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

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet 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.)

# 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

# OEM Operating Pattern (W eeks/Year): Annual Engine Volume (CPV): Components per Engine: Annual Component Volume: We ekly Component Volume:
Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **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)**

**1** 6.060 **$0.78 $38.52**  **$247.00 $988.00**  **$4.73 $0.16**  **$2.06 $6.95**  **0.00% 0.00%** 

**1** 0.000 **$0.00 $35.70**  **$75.00 $225.00**  **$0.00 $0.07**  **$0.42 $0.48**  **0.00% 0.00%** 

**1** 0.000 **$0.00 $35.70**  **$75.00 $450.00**  **$0.00 $0.15**  **$0.94 $1.09**  **0.00% 0.00%** 
**1** 0.000 **$0.00 $35.70**  **$75.00 $225.00**  **$0.00 $0.07**  **$0.42 $0.48**  **0.00% 0.00%** 

**1** 0.000 **$0.00 $35.70**  **$75.00 $225.00**  **$0.00 $0.07**  **$0.42 $0.48**  **0.00% 0.00%** 

**1** 0.000 **$0.00 $38.52**  **$150.00 $600.00**  **$0.00 $0.16**  **$1.25 $1.41**  **0.00% 0.00%**  

# 1 **450,000 9,574**  **47 450,000** 

**10**

**MANUFACTURING RATES MANUFACTURING COSTS** 

**1** 0.000 **$0.00 $46.52**  **$50.00 $300.00**  **$0.00 $0.19**  **$0.63 $0.82**  **0.00% 0.00%** 
**1** 0.000 **$0.00 $38.52**  **$150.00 $600.00**  **$0.00 $0.08**  **$1.25 $1.33**  **0.00% 0.00%** 
**1** 0.000 **$0.00 $38.52**  **$150.00 $600.00**  **$0.00 $0.08**  **$1.25 $1.33**  **0.00% 0.00%** 
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  

# $14.37

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

# Material **Labor Burden**  **TMC Scrap**  **SG&A**

**T1 or OEM Total Manufacturing Cost: $18.91**  **$4.09 $34.48**  **$57.48 $0.00**  **$0.00**

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

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

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

**Base Cost Impact to Vehicle: $18.91**  **$4.09 $34.48**  **$57.48 $0.00**  **$0.00**

**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** 



# Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 4,500,000**  **60 5.00%**  $0 **250**

**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**



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

# Packaging Cost Total: **$0.000** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:

Supplier Plant Location: OEM/T1 Classification: **Not Applicable** 

# Shipping Method: Packaging Specification: **NA**

**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 **Labor Burden** 

**0.00% 0.00%**  **0.00% $0.00**  **$6.95 $27.78**  **$18.91 $0.64**  **$8.23**

**0.00% 0.00%**  **0.00% $0.00**  **$0.48 $1.93**  **$0.00 $0.26**  **$1.67**

**0.00% 0.00%**  **0.00% $0.00**  **$1.09 $4.34**  **$0.00 $0.59**  **$3.75**
**0.00% 0.00%**  **0.00% $0.00**  **$0.48 $1.93**  **$0.00 $0.26**  **$1.67**

**0.00% 0.00%**  **0.00% $0.00**  **$0.48 $1.93**  **$0.00 $0.26**  **$1.67**

**0.00% 0.00%**  **0.00% $0.00**  **$1.41 $5.64**  **$0.00 $0.64**  **$5.00** 

# FOB Ship Point **North America**
**North America**

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

# Manufacturing Cost

**0.00% 0.00%**  **0.00% $0.00**  **$0.82 $3.28**  **$0.00 $0.78**  **$2.50**
**0.00% 0.00%**  **0.00% $0.00**  **$1.33 $5.32**  **$0.00 $0.32**  **$5.00**
**0.00% 0.00%**  **0.00% $0.00**  **$1.33 $5.32**  **$0.00 $0.32**  **$5.00**
**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00** 

# $14.37

**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**

## Supplier Account **Cost Purchase Price/** 

**Unit Purchase** 

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

**Price Net, End Item** 



# $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 **$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**

**Material Labor**  **Burden**

**$18.91 $4.09**  **$34.48**

**Profit ED&T**  **Total Mark-up $57.48** 

**$0.00 $0.00**  **$0.00 $57.48** 

0.00% 0.00% 0.00% **$0.00 $0.00**  **$0.00**

**$0.00 $0.00**  **$0.00 $57.48**  **$0 $0** 
**Packaging Cost: $0.00** 

**3 1** 



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

**Net Cost Impact to Vehicle: $57.48** **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** **)**



# 1 **6 57447** 

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

**Pads Pallet/Rack** 



# $0.00 0**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 )** 



# $27.78 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$1.93 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$4.34 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.93 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.93 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$5.64 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  

# Costs Broken Out Into Categories with Quantity per Assembly Taken into Account **Mark-up Cost**

**$3.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$5.32 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$5.32 $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 $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** 

**TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$57.48 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$57.48 2** 



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

# Process & Equipment Assumptions **Tooling/Fixturing and Gauge Assumptions**  **Days/ Week** 

**5**

**5**

**5**
**5**

**5**

**5** 

# Process Information

**5**
**5**
**5**
**5**
**5**
**5**

**5**
**5**
**5**
**5**
**5**

**5**

**5**

**5**

**5**

**5**

# 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 "** 



# 2 **10 100**  **47 4700**  **383 9.40**  **85% 451**  **7.99**

- - 1 30

**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 1 20

**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 1 45
**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 1 20

**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 1 20

**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 1 30 

# MANUFACTURING ASSUMPTIONS **Minimum Calculated Cycles Time Project Process Requirement**  **Projected Operating Pattern**

**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 4 180
**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 1 30
**2 10**  **100 47**  **4700 383**  **9.40 85%**  **451 7.99** 

- - 1 30
**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -**M u** **l i** **t 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 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**



# 1.0 **4.0 480**  **7.50** 2.00

**1.0 3.0**  **540 6.67**  1.00

**1.0 6.0**  **480 7.50**  2.00
**1.0 3.0**  **540 6.67**  1.00

**1.0 3.0**  **540 6.67**  1.00

**1.0 4.0**  **480 7.50**  2.00 

# Project Process Requirement

**1.0 6.0**  **480 7.50**  2.00
**1.0 4.0**  **480 7.50**  1.00
**1.0 4.0**  **480 7.50**  1.00
**1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

# Technology **Level: 6 Speed DCT vs 8 Speed DCT Transmission**  

# Vehicle Class: **Study Case#:**  **Sy stem Description:**  **6-8 Speed DCT Transmission** 

# Component Description: **Gears** 

# Component Quote Level: 02 Shafting

**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**

A 

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

1 **0**
2 **0**
3 **0**
4 **0** 

# B 

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

1 Pump Shaft **1** Make longer by 50mm
2 **0** Make longer by 50mm &



# GENERAL COMPONENT INFORMATION

3 Input Shaft, Inner **1** add additional spline for 7th gear
4 **0**

5 Input Shaft, Outer **1** Make longer by 50mm, add spline & press fit 6th or 8th input gear
6 **0**

7 Output Shaft, Upper **1** Make longer by 50mm, add spline for 7th & 8th
gears 8 **0**

9 Output Shaft, Lowe **1** Make longer by 50mm & add spline
10 **0**
11 Reverse Shaft **1** Make longer by 50mm
12 **0**
13 **0**
14 **0**
15 **0** 

# C 

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

1 **0**

2 **0**

# 3 **0**

4 **0**

5 **0**



# D 

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

1 **0**

2 **0**
3 **0**

4 **0**

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

7 **0**
8 **0**
9 **0**
10 **0**

11 **0**

12 **0**
13 **0**

14 **0**
15 **0**



# 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, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote Cost per BAse $100/Base

# Cost per 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

# 6 Speed DCT vs 8 Speed DCT Transmission

**6-8 Speed DCT Transmission** 

# Part Number:

**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** 



# #DIV/0! **0 1**  **#DIV/0! 0**  **1 #DIV/0!**  **0 1** 
**#DIV/0! 0**  **1**

Not Applicable A-Steel-8620, Bar 1-4" Not Applicable Not Applicable **240 0.5**  **1 #DIV/0!**  **0 1**  

# GENERAL MANUFACTURING INFORMATION

OEM Transmission Assembly A-Steel-8620, Bar 1-4" CNC Operator CNC Turning, HC, PP, Base **120 1**  **1**

**#DIV/0! 0**  **1**

OEM Transmission Assembly A-Steel-8620, Bar 1-4" CNC Operator CNC Turning, HC, PP, Base **120 1**  **2**

**#DIV/0! 0**  **1**

OEM Transmission Assembly A-Steel-8620, Bar 1-4" CNC Operator CNC Turning, HC, PP, Base **120 1**  **1**

**#DIV/0! 0**  **1**

OEM Transmission Assembly A-Steel-8620, Bar 1-4" CNC Operator CNC Turning, HC, PP, Base **120 1**  **1**

**#DIV/0! 0**  **1** OEM Transmission Assembly A-Steel-8620, Bar 1-4" CNC Operator CNC Turning, HC, PP, Base **120 1**  **1 #DIV/0!**  **0 1**  **#DIV/0! 0**  **1 #DIV/0!**  **0 1**  **#DIV/0! 0**  **1** 

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

**#DIV/0! 0**  **1**
**#DIV/0! 0**  **1**

# #DIV/0! **0 1** 
**#DIV/0! 0**  **1**

**#DIV/0! 0**  **1**



# Rack/Pallet Investment Amortization:

**Expendable Packaging in Piece Cost: Packaging Cost Total:**  

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

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet 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

# OEM Operating Pattern (W eeks/Year): Annual Engine Volume (CPV): Components per Engine: Annual Component Volume: We ekly Component Volume:
Estimated Product Life:**P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **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)** 

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 0.100 **$0.78 $0.00**  **$0.00 $0.00**  **$0.08 $0.00**  **$0.00 $0.08**  **0.00% 0.00%**  **0.00%**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A** 

# 9,574

**10**

**MANUFACTURING RATES MANUFACTURING COSTS**  **MARK-UP COSTS 47**  **450,000**
**1 450,000** 

**1** 0.150 **$0.78 $35.70**  **$75.00 $75.00**  **$0.12 $0.30**  **$0.63 $1.04**  **0.00% 0.00%**  **0.00%**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 1.000 **$0.78 $35.70**  **$75.00 $150.00**  **$0.78 $0.30**  **$1.25 $2.33**  **0.00% 0.00%**  **0.00%**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 0.150 **$0.78 $35.70**  **$75.00 $75.00**  **$0.12 $0.30**  **$0.63 $1.04**  **0.00% 0.00%**  **0.00%**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 0.150 **$0.78 $35.70**  **$75.00 $75.00**  **$0.12 $0.30**  **$0.63 $1.04**  **0.00% 0.00%**  **0.00%**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**1** 0.150 **$0.78 $35.70**  **$75.00 $75.00**  **$0.12 $0.30**  **$0.63 $1.04**  **0.00% 0.00%**  **0.00%**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

# 1 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit**

**T1 or OEM Total Manufacturing Cost: $1.33**  **$1.49 $3.75**  **$6.56 $0.00**  **$0.00 $0.00** 

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

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

----- ----- ----- **$0.00 $0.00**  **$0.00 &T1 or OEM Mark-Up Values:** 
**Base Cost Impact to Vehicle: $1.33**  **$1.49 $3.75**  **$6.56 $0.00**  **$0.00 $0.00** 

**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**



# Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 4,500,000**  **60 5.00%**  $0 **250** 1

**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** 



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

# Packaging Cost Total: **$0.000** 

# PACKAGING **CALCULATIONS:**

# OEM Plant Location:

Supplier Plant Location: OEM/T1 Classification: **Not Applicable** 

# Shipping Method: Packaging Specification: **NA**

**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 **Labor Burden** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**0.00% 0.00%**  **$0.00 $0.08**  **$0.08 $0.08**  **$0.00 $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **TOOLING & INVESTMENT** 

# Manufacturing Cost **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account MARK-UP COSTS**  **TOTAL COSTS North America** 
**North America**

**FOB Ship Point**

**0.00% 0.00%**  **$0.00 $1.04**  **$1.04 $0.12**  **$0.30 $0.63** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**0.00% 0.00%**  **$0.00 $2.33**  **$2.33 $0.78**  **$0.30 $1.25** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**0.00% 0.00%**  **$0.00 $1.04**  **$1.04 $0.12**  **$0.30 $0.63** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**0.00% 0.00%**  **$0.00 $1.04**  **$1.04 $0.12**  **$0.30 $0.63** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 
**0.00% 0.00%**  **$0.00 $1.04**  **$1.04 $0.12**  **$0.30 $0.63** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

# #N/A **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00** 

**Supplier Account Cost**  **Purchase Price/**

**Unit Purchase Price** 

**Net, PIA Purchase Price** 

**Net, End Item**



# $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 **$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**

**Material Labor**  **Burden**

**$1.33 $1.49**  **$3.75**

**ED&T Total Mark-up**  **$6.56**

**$0.00 $0.00**  **$6.56**

0.00% 0.00% **$0.00 $0.00**  **3 1** 



# Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.**  **$0.00 $0.00** 

**$0.00 $0.00**  **$6.56 $0**  **$0**
**Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $6.56** **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** **)**



# 6 **57447**

**Other #3 Pads Pallet/Rack** 



# 0 

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



# $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**

**$0.08 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  

# Mark-up Cost **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$1.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$2.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.04 $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 $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**

**TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$6.56 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$6.56 2** 



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

# Process & Equipment Assumptions **Tooling/Fixturing and Gauge Assumptions**  **Days/ Week** 

**5**
**5**
**5**
**5**

**5**
**5** 

# Process Information

**5**

**5**

**5**

**5**

**5**

**5**

**5**

**5**
**5**
**5**
**5**
**5**
**5**

**5**

**5**

# 5

**5**

**5**

# 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 "** 



# 2 **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96** 

- - 1 15
**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - 

# Minimum Calculated Cycles Time **Project Process Requirement Projected Operating Pattern**  **MANUFACTURING ASSUMPTIONS**

**2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96** 

- - 1 30

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96** 

- - 1 60

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96** 

- - 1 30

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96** 

- - 1 30

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96** 

- - 1 30
**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

# 2 **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - -

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -**M u** **l i** **t 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 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**



# 1.0 **1.0 #DIV/0!**  **#DIV/0!**

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**1.0 1.0**  **240 15.00**  0.50
**1.0 1.0**  **#DIV/0! #DIV/0!** 

- 

# Project Process Requirement

**1.0 1.0**  **120 30.00**  1.00

**1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**1.0 2.0**  **120 30.00**  1.00

**1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**1.0 1.0**  **120 30.00**  1.00

**1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**1.0 1.0**  **120 30.00**  1.00

**1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **120 30.00**  1.00
**1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

# 1.0 **1.0 #DIV/0!**  **#DIV/0!**

-

**1.0 1.0**  **#DIV/0! #DIV/0!** 

- **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

# Technology **Level: 6 Speed DCT vs 8 Speed DCT Transmission**  

# Vehicle Class: **Study Case#:**  **Sy stem Description:**  **6-8 Speed DCT Transmission** 

# Component Description: **Gears** 

# Component Quote Level: 03 Housing / Case

**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**

A 

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

1 Case, Front **1** Assemble added components
2 **0**

3 Case, Rear **1** Assemble added components
4 **0** 

# B 

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

**GENERAL COMPONENT INFORMATION**

1 Case, Front **1** Machined - additional bores & ports
2 **0**

3 Case, Rear **1** Machined - 50mm longer housing & additional bores & ports
4 **0**
5 **0**
6 **0**
7 **0**
8 **0** 

# C 

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

1 **0**

2 **0**
3 **0**

4 **0**

5 **0**



# D 

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

1 **0**

# 2 **0**

3 **0**

4 **0**

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

7 **0**
8 **0**
9 **0**
10 **0**

11 **0**

12 **0**
13 **0**

14 **0**
15 **0**



# 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, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote Cost per 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

# 6 Speed DCT vs 8 Speed DCT Transmission

**6-8 Speed DCT Transmission** 

# Part Number:

**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** **t i** **p l** **i e** **r**



# OEM Transmission Assembly Not Applicable General Assembly Transfer Asm line, Transmission cases **120 1**  **2 1** 

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

OEM Transmission Assembly Not Applicable General Assembly Transfer Asm line, Transmission cases **120 1**  **2 1** 

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

Transfer machining line, 

# GENERAL MANUFACTURING INFORMATION

OEM Transmission Assembly Aluminum-A380, Cast CNC Operator Transmission cases, OEM **120 1**  **1 1** 

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

OEM Transmission Assembly Aluminum-A380, Cast CNC Operator Transfer machining line, Transmission cases, OEM **120 1**  **1 1** 

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

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

**#DIV/0! 0**  **1 1** 
**#DIV/0! 0**  **1 1** 
**#DIV/0! 0**  **1 1** 
**#DIV/0! 0**  **1 1** 

**#DIV/0! 0**  **1 1** 

# Rack/Pallet Investment Amortization:

**Expendable Packaging in Piece Cost: Packaging Cost Total:**  

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

Piece Price, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet 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

# OEM Operating Pattern (W eeks/Year): Annual Engine Volume (CPV): Components per Engine: Annual Component Volume: We ekly Component Volume: Packaging Specification:
Estimated Product Life:**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)** 

0.000 **$0.00 $35.51**  **$75.00 $150.00**  **$0.00 $0.30**  **$1.25 $1.55**  **0.00% 0.00%**  **0.00%**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

0.000 **$0.00 $35.51**  **$75.00 $150.00**  **$0.00 $0.30**  **$1.25 $1.55**  **0.00% 0.00%**  **0.00%**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A** 

# 1 **450,000 9,574**  **47 450,000** 

**10**

**MANUFACTURING RATES MANUFACTURING COSTS**  **MARK-UP COSTS**

1.000 **$1.10 $35.70**  **$700.00 $700.00**  **$1.10 $0.30**  **$5.83 $7.23**  **0.00% 0.00%**  **0.00%**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

4.000 **$1.10 $35.70**  **$700.00 $700.00**  **$4.40 $0.30**  **$5.83 $10.53**  **0.00% 0.00%**  **0.00%**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**
0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A**

# Material **Labor Burden**  **TMC Scrap**  **SG&A Profit** 

**T1 or OEM Total Manufacturing Cost: $5.50**  **$1.19 $14.17**  **$20.85 $0.00**  **$0.00 $0.00** 

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

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

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

**Base Cost Impact to Vehicle: $5.50**  **$1.19 $14.17**  **$20.85 $0.00**  **$0.00 $0.00** 

**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** 



# Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 4,500,000**  **60 5.00%**  $0 **250** 1

**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** 



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

# Packaging Cost Total: **$0.000**

# OEM Plant Location:

Supplier Plant Location: OEM/T1 Classification: **Not Applicable** 

# Shipping Method: Packaging Specification: **NA**

**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 **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 )** 



# 0.00% **0.00% $0.00**  **$1.55 $1.55**  **$0.00 $0.30**  **$1.25 $1.55** 

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**0.00% 0.00%**  **$0.00 $1.55**  **$1.55 $0.00**  **$0.30 $1.25**  **$1.55**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** 

# FOB Ship Point **North America**
**North America**

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

# Manufacturing Cost

**0.00% 0.00%**  **$0.00 $7.23**  **$7.23 $1.10**  **$0.30 $5.83**  **$7.23**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**0.00% 0.00%**  **$0.00 $10.53**  **$10.53 $4.40**  **$0.30 $5.83**  **$10.53**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**Supplier Account Cost**  **Purchase Price/**

**Unit Purchase** 

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

**Price Net, End Item** 



# $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**  **$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** 

**Material Labor**  **Burden TMC** 

**$5.50 $1.19**  **$14.17 $20.85** 

**ED&T Total Mark-up**  **$20.85**

**$0.00 $0.00**  **$20.85**

0.00% 0.00% **$0.00 $0.00** 

**$0.00 $0.00**  **$20.85 $0**  **$0**
**Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $20.85**  **3 1** 



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



# 6 **57447**

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



# 0

# 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

**$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** 

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

**$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**  **$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**

# Scrape **SG&A Profit**  **ED&T Mark-up**  **Total**
**$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$20.85 2** 



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

# Tooling/Fixturing 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** 



# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113**

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 



# MANUFACTURING ASSUMPTIONS **Minimum Calculated Cycles Time Projected Operating Pattern** 

**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** **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 i** **t 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 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**



# 31.96

- - 1 60 **1.0 2.0**  **120 30.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**31.96**

- - 1 60 **1.0 2.0**  **120 30.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- 

# Minimum Calculated Cycles Time **Project Process Requirement**

**31.96**

- - 1 30 **1.0 1.0**  **120 30.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**31.96**

- - 1 30 **1.0 1.0**  **120 30.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

# Technology **Level: Vehicle Class:**  **Study Case#:**  **Sy stem Description:**  **Component Description: Component Quote Level:** 

**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**



# A 

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

1 7th Spd Synchronizer Assembly **1**
2 8th Spd Synchronizer Assembly **1**
**0**
3 7th Spd Gear Shift Fork Assembly **1**
4 8th Spd Gear Shift Fork Assembly **1**
**0**
**0** 

# B 

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

**GENERAL COMPONENT INFORMATION**

**New Components: 0** 

1 7th Spd Gear Synchronizer **2**

2 7th Spd Gear Synchronizer **2**

3 7th Spd Gear Synchronizer **2**

4 7th Spd Gear Synchronizer **1**

5 7th Spd Gear Synchronizer **1**

**0**
6 7th Spd Gear Hub, Shift Collar **1**
7 7th Spd Gear Hub, Shift Collar **1**
**0**
8 7th Spd Gear Shift Hub **1**
9 7th Spd Gear Shift Hub **1**
**0**
10 7th Spd Gear Shift Fork Assemblies **1**
11 7th Spd Gear Shift Fork Assemblies **1**
12 7th Spd Gear Shift Fork Assemblies **1**

13 7th Spd Gear Shift Fork Assemblies **1**

14 7th Spd Gear Shift Fork Assemblies **1**
15 7th Spd Gear Shift Fork Assemblies **1**

# 16 7th Spd Gear Shift Fork Assemblies **1**

17 7th Spd Gear Shift Fork Assemblies **1**

**0**

18 7th Spd Gear Shift Fork Piston Asm

(includes Cylinder Liners) **2**

19 7th Spd Gear Shift Fork Piston Asm

(includes Cylinder Liners) **2**

**0**
20 7th Spd Spool Valve **1**
21 7th Spd Spool Valve **1**
22 7th Spd Spool Valve **1**
23 7th Spd Spool Valve **1**
**0**

24 8th Spd Gear Synchronizer **2**

25 8th Spd Gear Synchronizer **2**

26 8th Spd Gear Synchronizer **2**

27 8th Spd Gear Synchronizer **1**

28 8th Spd Gear Synchronizer **1**

**0**
29 8th Spd Gear Hub, Shift Collar **1**
30 8th Spd Gear Hub, Shift Collar **1**
**0**
31 8th Spd Gear Shift Hub **1**
32 8th Spd Gear Shift Hub **1**
**0**
33 8th Spd Gear Shift Fork Assemblies **1**
34 8th Spd Gear Shift Fork Assemblies **1**
35 8th Spd Gear Shift Fork Assemblies **1**

36 8th Spd Gear Shift Fork Assemblies **1**

37 8th Spd Gear Shift Fork Assemblies **1**
38 8th Spd Gear Shift Fork Assemblies **1**
39 8th Spd Gear Shift Fork Assemblies **1**

40 8th Spd Gear Shift Fork Assemblies **1**

**0**

41 8th Spd Gear Shift Fork Piston Asm

(includes Cylinder Liners) **2**

42 8th Spd Gear Shift Fork Piston Asm

(includes Cylinder Liners) **2**

**0**
43 8th Spd Spool Valve **1**
44 8th Spd Spool Valve **1**
45 8th Spd Spool Valve **1**
46 8th Spd Spool Valve **1**
**0**
**0 Modified Components:**  **0**
47 Valve Body **1**
**0**
48 Valve Body Asm **1**
**0**

# 49 Transfer Plate **1**

50 Valve Body Gasket Plate **1**
51 Valve Body Cover **1**
**0**
52 Oil Pump Distributor **1**
53 Oil Pump Distributor **1**
**0**
**0** 

# C 

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

1 **0**

2 **0**
3 **0**

4 **0**

5 **0**



# D 

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

1 7th spd, Epoxy glue for magnet 020799-N0902-02 **2**

2 7th spd, Magnet 020799-N0902-01 **2**
3 7th spd, Shift Fork, Race Large 020790-N0902-01a **1**

4 7th spd, Shift Fork, Race Small 020790-N0902-02a **1**

5 7th spd, Shift Fork, Cage Large 020790-N0902-05a **1**
6 7th spd, Shift Fork, Cage Small 020790-N0902-06a **1**

7 7th spd, Shift Fork, Magnet Cover 020799-N0902-03 **1**
**0**

1 8th spd, Epoxy glue for magnet 020799-N0902-02 **2**

2 8th spd, Magnet 020799-N0902-01 **2**
3 8th spd, Shift Fork, Race Large 020790-N0902-01a **1**

4 8th spd, Shift Fork, Race Small 020790-N0902-02a **1**

5 8th spd, Shift Fork, Cage Large 020790-N0902-05a **1**
6 8th spd, Shift Fork, Cage Small 020790-N0902-06a **1**

7 8th spd, Shift Fork, Magnet Cover 020799-N0902-03 **1**
**0**
8 7th Spd Synchro. Parts **1**
9 8th Spd Synchro. Parts **1**
**0**
10 7th Spd Solenoid **1**

11 8th Spd Solenoid **1**
**0**

12 7th Spd Gear Misc Parts **1**
13 8th Spd Gear Misc Parts **1**
**0**
**0**

# 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, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote Cost per 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

# 6 Speed DCT vs 8 Speed DCT Transmission

**6-8 Speed DCT Transmission**
**Gears**
04 Mechanical Controls Assembly

**Primary Process Description OEM/Supplier Classification**  **Material Specification** 



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

Assemble outer and center rings, springs, clips T1 Moderate Assembly Complexity Not Applicable Assemble outer and center rings, springs, clips T1 Moderate Assembly Complexity Not Applicable

Assemble cages, races, magnets and magnet cover T1 Moderate Assembly Complexity Not Applicable Assemble cages, races, magnets and magnet cover T1 Moderate Assembly Complexity Not Applicable 

# GENERAL MANUFACTURING INFORMATION

Outer Ring, Forge, trim and temper T1 Moderate Assembly Complexity A-Steel-4140, Bar

Outer Ring, Turning T1 Moderate Assembly Complexity Not Applicable

Outer Ring, Teeth forming; broach T1 Moderate Assembly Complexity Not Applicable

Center Ring, Forging T1 Moderate Assembly Complexity A-Steel-4140, Bar

Center Ring, Turning T1 Moderate Assembly Complexity Not Applicable

Forge, trim and temper T2/T3 Forge, SSLC A-Steel-4140, Bar Turning T2/T3 CNC Turning, MSMC Not Applicable

Forge, trim and temper T2/T3 Forge, SSLC A-Steel-4140, Bar Turning T2/T3 CNC Turning, MSMC Not Applicable

Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil Clamp and bend T1 Moderate Assembly Complexity Not Applicable
Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil

Clamp, bend and spray coat T1 Moderate Assembly Complexity WC 2, Spray

Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil Clamp and bend T1 Moderate Assembly Complexity Not Applicable

# Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil

We ld shift fork components together T1 Moderate Assembly Complexity Not Applicable

Casting T1 Moderate Assembly Complexity MC-Steel-1000S, Coil

Machining T1 Moderate Assembly Complexity Not Applicable

Cut to length T1 Moderate Assembly Complexity AlSi.13
Machine T1 Moderate Assembly Complexity Not Applicable
Polish T1 Moderate Assembly Complexity Not Applicable Paint/coat T1 Moderate Assembly Complexity Plating, Fuel Rail

Outer Ring, Forge, trim and temper T1 Moderate Assembly Complexity A-Steel-4140, Bar

Outer Ring, Turning T1 Moderate Assembly Complexity Not Applicable

Outer Ring, Teeth forming; broach T1 Moderate Assembly Complexity Not Applicable

Center Ring, Forging T1 Moderate Assembly Complexity A-Steel-4140, Bar

Center Ring, Turning T1 Moderate Assembly Complexity Not Applicable

Forge, trim and temper T2/T3 Forge, SSLC A-Steel-4140, Bar Turning T2/T3 CNC Turning, MSMC Not Applicable

Forge, trim and temper T2/T3 Forge, SSLC A-Steel-4140, Bar Turning T2/T3 CNC Turning, MSMC Not Applicable

Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil Clamp and bend T1 Moderate Assembly Complexity Not Applicable
Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil

Clamp, bend and spray coat T1 Moderate Assembly Complexity WC 2, Spray

Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil Clamp and bend T1 Moderate Assembly Complexity Not Applicable
Fine Blank T1 Moderate Assembly Complexity MC-Steel-1000S, Coil

We ld shift fork components together T1 Moderate Assembly Complexity Not Applicable

Casting T1 Moderate Assembly Complexity MC-Steel-1000S, Coil

Machining T1 Moderate Assembly Complexity Not Applicable

Cut to length T1 Moderate Assembly Complexity AlSi.13
Machine T1 Moderate Assembly Complexity Not Applicable
Polish T1 Moderate Assembly Complexity Not Applicable Paint/coat T1 Moderate Assembly Complexity Plating, Fuel Rail

Machine (2) additional valve bores, revised worm trails OEM Transmission Assembly MC-Steel-1018, Bar

Assemble (2) added spool valve, springs, clips, etc. OEM Transmission Assembly Not Applicable

# Wo rm trail revisions OEM Transmission Assembly MC-Steel-1018, Bar

Modified to accommodate the revised worm trails and porting T1 Moderate Assembly Complexity LC-Steel-1008 Larger stamping to accommodate the larger valve body T1 Moderate Assembly Complexity LC-Steel-1008 Additional tubing Add distributor for (4) additional gears T1 Moderate Assembly Complexity Additional distributors Add tubing for (4) additional gears T1 Moderate Assembly Complexity Additional tubing



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

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

Commodity S Price is estimated Commodity S Price is estimated
Manufactured sac Manufactured sac Manufactured sac Manufactured sac Manufactured sac

Commodity S Price is estimated Commodity S Price is estimated
Manufactured sac Manufactured sac 

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

"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

"Alpha

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

Manufactured sac Manufactured sac Manufactured sac Manufactured sac

Springs, rings, clips S Springs, rings, clips S

S
S

Springs, seals, clips, retaining rings S Springs, seals, clips, retaining rings S 

# Subassembly.

# 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, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote Cost per 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

3.344166667 1.1
0.2975
1.946666667
1.845 0.595
1.25

1.1 1.1
0.1625 0.1625
1.625 1.625
3

# OEM Operating Pattern (W eeks/Year):

**Part Number:**

**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 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)**

General Assembly Mech. Assembly, MC **127 3**  **3 1**  0.000 **$0.00 $35.51**  General Assembly Mech. Assembly, MC **127 3**  **3 1**  0.000 **$0.00 $35.51** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  General Assembly Mech. Assembly, MC **160 1**  **1 1**  0.000 **$0.00 $35.51**  General Assembly Mech. Assembly, MC **160 1**  **1 1**  0.000 **$0.00 $35.51** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  

# MANUFACTURING RATES

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 

Forging Operator Forge, SS **360 2**  **2 1**  0.500 **$0.78 $38.52** 

CNC Operator CNC Turning, HC, PP, Base **288 1**  **2 1**  0.000 **$0.00 $35.70** 

CNC Operator CNC Turning, HC, PP, Base **360 1**  **1 1**  0.000 **$0.00 $35.70** 

Forging Operator Forge, SS **200 1**  **1 1**  0.750 **$0.78 $38.52** 

CNC Operator CNC Turning, HC, PP, Base **164 1**  **1 1**  0.000 **$0.00 $35.70** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Forging Operator Forge, SS **240 1**  **1 1**  1.550 **$0.78 $38.52**  CNC Operator CNC Turning, HC, PP, Base **180 1**  **1 1**  0.000 **$0.00 $35.70** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Forging Operator Forge, SS **240 1**  **1 1**  1.300 **$0.78 $38.52**  CNC Operator CNC Turning, HC, PP, Base **200 1**  **1 1**  0.000 **$0.00 $35.70** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Cut/Punch/Forming Operator Stamp/Form, MS **300 1**  **1 1**  1.486 **$0.55 $42.18**  Cut/Punch/Forming Operator Stamp/Form, MS **514 1**  **1 1**  0.000 **$0.00 $42.18**  Cut/Punch/Forming Operator Stamp/Form, MS **300 1**  **1 1**  0.961 **$0.55 $42.18** 

Cut/Punch/Forming Operator Stamp/Form, MS **240 1**  **1 1**  0.015 **$250.00 $42.18** 

Cut/Punch/Forming Operator Stamp/Form, MS **400 1**  **1 1**  0.107 **$0.55 $42.18**  Cut/Punch/Forming Operator Stamp/Form, MS **720 1**  **1 1**  0.000 **$0.00 $42.18** 

# Cut/Punch/Forming Operator Stamp/Form, MS **400 1**  **1 1**  0.013 **$0.55 $42.18** 

General Assembly Mech. Assembly, MC **185 1**  **1 1**  0.000 **$0.00 $35.51** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 

Mold/Cast/Sinter Operator Sand Cast Line, SS **225 1**  **1 1**  0.100 **$0.55 $43.52** 

Milling/Planing Operator CNC Machining, MHC **360 1**  **1 1**  0.000 **$0.00 $35.37** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Extruding/Drawing Operator Stamp/Form, SMS, LMC **3600 1**  **1 1**  1.240 **$1.14 $54.35**  Milling/Planing Operator CNC Machining, MHC **113 2**  **1 1**  0.000 **$0.00 $35.37**  Milling/Planing Operator Diecast, LMC **180 1**  **1 1**  0.000 **$0.00 $35.37**  Plating/Coating Operator Plate/Finish, SMS, MHC **300 1**  **1 1**  0.000 **$20.00 $55.17** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 

Forging Operator Forge, SS **180 1**  **1 1**  0.500 **$0.78 $38.52** 

CNC Operator CNC Turning, HC, PP, Base **288 1**  **2 1**  0.000 **$0.00 $35.70** 

CNC Operator CNC Turning, HC, PP, Base **360 1**  **1 1**  0.000 **$0.00 $35.70** 

Forging Operator Forge, SS **200 1**  **1 1**  0.750 **$0.78 $38.52** 

CNC Operator CNC Turning, HC, PP, Base **164 1**  **1 1**  0.000 **$0.00 $35.70** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Forging Operator Forge, SS **240 1**  **1 1**  1.550 **$0.78 $38.52**  CNC Operator CNC Turning, HC, PP, Base **180 1**  **1 1**  0.000 **$0.00 $35.70** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Forging Operator Forge, SS **240 1**  **1 1**  1.300 **$0.78 $38.52**  CNC Operator CNC Turning, HC, PP, Base **200 1**  **1 1**  0.000 **$0.00 $35.70** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Cut/Punch/Forming Operator Stamp/Form, MS **300 1**  **1 1**  1.486 **$0.55 $42.18**  Cut/Punch/Forming Operator Stamp/Form, MS **514 1**  **1 1**  0.000 **$0.00 $42.18**  Cut/Punch/Forming Operator Stamp/Form, MS **300 1**  **1 1**  0.961 **$0.55 $42.18** 

Cut/Punch/Forming Operator Stamp/Form, MS **240 1**  **1 1**  0.015 **$250.00 $42.18** 

Cut/Punch/Forming Operator Stamp/Form, MS **400 1**  **1 1**  0.107 **$0.55 $42.18**  Cut/Punch/Forming Operator Stamp/Form, MS **720 1**  **1 1**  0.000 **$0.00 $42.18**  Cut/Punch/Forming Operator Stamp/Form, MS **400 1**  **1 1**  0.013 **$0.55 $42.18** 

General Assembly Mech. Assembly, MC **185 1**  **1 1**  0.000 **$0.00 $35.51** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 

Mold/Cast/Sinter Operator Sand Cast Line, SS **225 1**  **1 1**  0.100 **$0.55 $43.52** 

Milling/Planing Operator CNC Machining, MHC **360 1**  **1 1**  0.000 **$0.00 $35.37** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  Extruding/Drawing Operator Stamp/Form, SMS, LMC **3600 1**  **1 1**  1.240 **$1.14 $54.35**  Milling/Planing Operator CNC Machining, MHC **113 2**  **1 1**  0.000 **$0.00 $35.37**  Milling/Planing Operator Diecast, LMC **180 1**  **1 1**  0.000 **$0.00 $35.37**  Plating/Coating Operator Plate/Finish, SMS, MHC **300 1**  **1 1**  0.000 **$20.00 $55.17** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  CNC Mill Operator CNC Milling Machine **120 1**  **1 1**  1.000 **$1.10 $35.70** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  General Assembly Assembly Station **120 2**  **2 1**  0.000 **$0.00 $37.50** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 

# Not Applicable Not Applicable **3600 1**  **1 1**  1.000 **$1.10 $0.00** 

Not Applicable Not Applicable **3600 1**  **1 1**  0.250 **$0.65 $0.00**  Not Applicable Not Applicable **3600 1**  **1 1**  2.500 **$0.65 $0.00**  Not Applicable Not Applicable **#DIV/0! 0**  **1 1**  0.000 **#N/A $0.00**  Not Applicable Not Applicable **3600 1**  **1 1**  0.000 **#N/A $0.00**  Not Applicable Not Applicable **3600 1**  **1 1**  0.000 **#N/A $0.00** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A** 



# "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

Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark

- up Calculations.

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

**T1 or OEM Total Manufacturing Cost:**

# (SAC) **&T1 or OEM Mark-Up Values:**
**Base Cost Impact to Vehicle:**

**Cost per Piece**



# Rack/Pallet Investment Amortization: **$0.000**

**Cost per Piece**



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

# Packaging Cost Total: **$0.000** 

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

# OEM Operating Pattern (W eeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location: Components per Engine: OEM/T1 Classification: Annual Component Volume: Shipping Method: We ekly Component Volume: Packaging Specification:
Estimated Product Life:

**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**

**$125.00 $375.00**  **$0.00 $0.84**  **$2.95 $3.79**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.59**  **$125.00 $375.00**  **$0.00 $0.84**  **$2.95 $3.79**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.59** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$125.00 $125.00**  **$0.00 $0.22**  **$0.78 $1.00**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.16**  **$125.00 $125.00**  **$0.00 $0.22**  **$0.78 $1.00**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.16** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  

# 9,574

**10**

**MANUFACTURING COSTS MARK-UP COSTS** 

**47 450,000** 
**1 450,000** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**$115.72 $231.44**  **$0.39 $0.21**  **$0.64 $1.25**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.19** 

**$75.00 $150.00**  **$0.00 $0.12**  **$0.52 $0.64**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.10** 

**$75.00 $75.00**  **$0.00 $0.10**  **$0.21 $0.31**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.05** 

**$115.72 $115.72**  **$0.59 $0.19**  **$0.58 $1.36**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.21** 

**$75.00 $75.00**  **$0.00 $0.22**  **$0.46 $0.68**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.10** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$115.72 $115.72**  **$1.21 $0.16**  **$0.48 $1.85**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.19**  **$75.00 $75.00**  **$0.00 $0.20**  **$0.42 $0.61**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.09** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$115.72 $115.72**  **$1.01 $0.16**  **$0.48 $1.66**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.17**  **$75.00 $75.00**  **$0.00 $0.18**  **$0.38 $0.55**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.08** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$83.80 $83.80**  **$0.82 $0.14**  **$0.28 $1.24**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.19**  **$83.80 $83.80**  **$0.00 $0.08**  **$0.16 $0.24**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.04**  **$83.80 $83.80**  **$0.53 $0.14**  **$0.28 $0.95**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.15** 

**$83.80 $83.80**  **$3.75 $0.18**  **$0.35 $4.27**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.66** 

**$83.80 $83.80**  **$0.06 $0.11**  **$0.21 $0.37**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.06**  **$83.80 $83.80**  **$0.00 $0.06**  **$0.12 $0.17**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.03** 

# $83.80 **$83.80 $0.01**  **$0.11 $0.21**  **$0.32 0.50%**  **6.50% 6.00%**  **2.50% 15.50%**  **$0.05**

**$125.00 $125.00**  **$0.00 $0.19**  **$0.68 $0.87**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.13** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**$351.62 $351.62**  **$0.06 $0.19**  **$1.56 $1.81**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.28** 

**$53.25 $53.25**  **$0.00 $0.10**  **$0.15 $0.25**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.04** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$60.65 $60.65**  **$1.41 $0.02**  **$0.02 $1.45**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.22**  **$53.25 $53.25**  **$0.00 $0.63**  **$0.47 $1.10**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.17**  **$116.73 $116.73**  **$0.00 $0.20**  **$0.65 $0.84**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.13**  **$125.00 $125.00**  **$0.00 $0.18**  **$0.42 $0.60**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.09** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**$115.72 $115.72**  **$0.39 $0.21**  **$0.64 $1.25**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.19** 

**$75.00 $150.00**  **$0.00 $0.12**  **$0.52 $0.64**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.10** 

**$75.00 $75.00**  **$0.00 $0.10**  **$0.21 $0.31**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.05** 

**$115.72 $115.72**  **$0.59 $0.19**  **$0.58 $1.36**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.21** 

**$75.00 $75.00**  **$0.00 $0.22**  **$0.46 $0.68**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.10** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$115.72 $115.72**  **$1.21 $0.16**  **$0.48 $1.85**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.19**  **$75.00 $75.00**  **$0.00 $0.20**  **$0.42 $0.61**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.09** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$115.72 $115.72**  **$1.01 $0.16**  **$0.48 $1.66**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.17**  **$75.00 $75.00**  **$0.00 $0.18**  **$0.38 $0.55**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.08** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$83.80 $83.80**  **$0.82 $0.14**  **$0.28 $1.24**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.19**  **$83.80 $83.80**  **$0.00 $0.08**  **$0.16 $0.24**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.04**  **$83.80 $83.80**  **$0.53 $0.14**  **$0.28 $0.95**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.15** 

**$83.80 $83.80**  **$3.75 $0.18**  **$0.35 $4.27**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.66** 

**$83.80 $83.80**  **$0.06 $0.11**  **$0.21 $0.37**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.06**  **$83.80 $83.80**  **$0.00 $0.06**  **$0.12 $0.17**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.03**  **$83.80 $83.80**  **$0.01 $0.11**  **$0.21 $0.32**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.05** 

**$125.00 $125.00**  **$0.00 $0.19**  **$0.68 $0.87**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.13** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**$351.62 $351.62**  **$0.06 $0.19**  **$1.56 $1.81**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.28** 

**$53.25 $53.25**  **$0.00 $0.10**  **$0.15 $0.25**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.04** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$60.65 $60.65**  **$1.41 $0.02**  **$0.02 $1.45**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.22**  **$53.25 $53.25**  **$0.00 $0.63**  **$0.47 $1.10**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.17**  **$116.73 $116.73**  **$0.00 $0.20**  **$0.65 $0.84**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.13**  **$125.00 $125.00**  **$0.00 $0.18**  **$0.42 $0.60**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.09** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$233.60 $233.60**  **$1.10 $0.30**  **$1.95 $3.34**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$75.00 $150.00**  **$0.00 $0.63**  **$1.25 $1.88**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

# $0.00 **$0.00 $1.10**  **$0.00 $0.00**  **$1.10 0.00%**  **0.00% 0.00%**  **0.00% 0.00%**  **$0.00**

**$0.00 $0.00**  **$0.16 $0.00**  **$0.00 $0.16**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.03**  **$0.00 $0.00**  **$1.63 $0.00**  **$0.00 $1.63**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.25**  **$0.00 $0.00**  **#N/A #DIV/0!**  **#DIV/0! #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **$0.00 $0.00**  **$2.00 $0.00**  **$0.00 $2.00**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.31**  **$0.00 $0.00**  **$1.00 $0.00**  **$0.00 $1.00**  **0.50% 6.50%**  **6.00% 2.50%**  **15.50% $0.16** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**Supplier Account Cost**  **Purchase Price/**

**Unit**



# $0.00 $0.01 **$0.00** $0.01 **$1.13** $1.13 **$1.13** $1.13 **$0.59** $0.59 **$0.58** $0.58 **$0.05** $0.05 **$0.00** $0.00 **$0.00** $0.01 **$0.00** $0.01 **$1.13** $1.13 **$1.13** $1.13 **$0.59** $0.59 **$0.58** $0.58 **$0.05** $0.05 **$0.00** $0.00 **$0.00** $1.95 **$0.00** $1.95 **$0.00** $0.00 **$0.00** $9.00 **$0.00** $9.00 **$0.00** $0.00 **$0.00** $1.20 **$0.00** $1.20 **$0.00** $0.00 **$0.00** $0.00

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

**T1 or OEM Total Manufacturing Cost: $58.87**  **$12.23 $36.26**  **$107.36 $0.33**  **$4.50 $4.04**  **$1.53 $10.40** 

# T1 or OEM Mark-Up Rates:

----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

**&T1 or OEM Mark-Up Values: (6.96)** 

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

**Base Cost Impact to Vehicle: $51.91**  **$12.23 $36.26**  **$100.40 $0.33**  **$4.50 $4.04**  **$1.53 $10.40** 
**Packaging Cost: Net Cost Impact to Vehicle:** 

**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** **)**



# $0 **0.00% 4,500,000**  **60 5.00%**  $0 **250** 1 **6 57447** 

**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** 



# $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

# Not Applicable

**NA 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 **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**

**$4.38 $4.38**  **$0.00 $0.84**  **$2.95 $3.79**  **$0.02 $0.25**  **$0.23 $4.38**  **$4.38 $0.00**  **$0.84 $2.95**  **$3.79 $0.02**  **$0.25 $0.23** 
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.16**  **$1.16 $0.00**  **$0.22 $0.78**  **$1.00 $0.01**  **$0.07 $0.06**  **$1.16 $1.16**  **$0.00 $0.22**  **$0.78 $1.00**  **$0.01 $0.07**  **$0.06**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**TOOLING & INVESTMENT** 

# Manufacturing Cost **Mark-up Cost Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **TOTAL COSTS North America** 
**North America**

**FOB Ship Point**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$1.44 $2.88**  **$0.78 $0.43**  **$1.29 $2.49**  **$0.01 $0.16**  **$0.15**

**$0.74 $1.49**  **$0.00 $0.25**  **$1.04 $1.29**  **$0.01 $0.08**  **$0.08**

**$0.36 $0.71**  **$0.00 $0.20**  **$0.42 $0.61**  **$0.00 $0.04**  **$0.04**

**$1.57 $1.57**  **$0.59 $0.19**  **$0.58 $1.36**  **$0.01 $0.09**  **$0.08**

**$0.78 $0.78**  **$0.00 $0.22**  **$0.46 $0.68**  **$0.00 $0.04**  **$0.04**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $2.04**  **$2.04 $1.21**  **$0.16 $0.48**  **$1.85 $0.01**  **$0.11 $0.07**  **$0.70 $0.70**  **$0.00 $0.20**  **$0.42 $0.61**  **$0.00 $0.04**  **$0.04**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.83**  **$1.83 $1.01**  **$0.16 $0.48**  **$1.66 $0.00**  **$0.10 $0.07**  **$0.63 $0.63**  **$0.00 $0.18**  **$0.38 $0.55**  **$0.00 $0.04**  **$0.03**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.43**  **$1.43 $0.82**  **$0.14 $0.28**  **$1.24 $0.01**  **$0.08 $0.07**  **$0.28 $0.28**  **$0.00 $0.08**  **$0.16 $0.24**  **$0.00 $0.02**  **$0.01 $1.10**  **$1.10 $0.53**  **$0.14 $0.28**  **$0.95 $0.00**  **$0.06 $0.06** 

**$4.94 $4.94**  **$3.75 $0.18**  **$0.35 $4.27**  **$0.02 $0.28**  **$0.26**

**$0.43 $0.43**  **$0.06 $0.11**  **$0.21 $0.37**  **$0.00 $0.02**  **$0.02 $0.20**  **$0.20 $0.00**  **$0.06 $0.12**  **$0.17 $0.00**  **$0.01 $0.01** 

# $0.37 **$0.37 $0.01**  **$0.11 $0.21**  **$0.32 $0.00**  **$0.02 $0.02** 

**$1.00 $1.00**  **$0.00 $0.19**  **$0.68 $0.87**  **$0.00 $0.06**  **$0.05**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$2.09 $4.18**  **$0.11 $0.39**  **$3.13 $3.62**  **$0.02 $0.24**  **$0.22**

**$0.28 $0.57**  **$0.00 $0.20**  **$0.30 $0.49**  **$0.00 $0.03**  **$0.03**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.67**  **$1.67 $1.41**  **$0.02 $0.02**  **$1.45 $0.01**  **$0.09 $0.09**  **$1.27 $1.27**  **$0.00 $0.63**  **$0.47 $1.10**  **$0.01 $0.07**  **$0.07 $0.98**  **$0.98 $0.00**  **$0.20 $0.65**  **$0.84 $0.00**  **$0.05 $0.05**  **$0.69 $0.69**  **$0.00 $0.18**  **$0.42 $0.60**  **$0.00 $0.04**  **$0.04**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$1.44 $2.88**  **$0.78 $0.43**  **$1.29 $2.49**  **$0.01 $0.16**  **$0.15**

**$0.74 $1.49**  **$0.00 $0.25**  **$1.04 $1.29**  **$0.01 $0.08**  **$0.08**

**$0.36 $0.71**  **$0.00 $0.20**  **$0.42 $0.61**  **$0.00 $0.04**  **$0.04**

**$1.57 $1.57**  **$0.59 $0.19**  **$0.58 $1.36**  **$0.01 $0.09**  **$0.08**

**$0.78 $0.78**  **$0.00 $0.22**  **$0.46 $0.68**  **$0.00 $0.04**  **$0.04**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $2.04**  **$2.04 $1.21**  **$0.16 $0.48**  **$1.85 $0.01**  **$0.11 $0.07**  **$0.70 $0.70**  **$0.00 $0.20**  **$0.42 $0.61**  **$0.00 $0.04**  **$0.04**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.83**  **$1.83 $1.01**  **$0.16 $0.48**  **$1.66 $0.00**  **$0.10 $0.07**  **$0.63 $0.63**  **$0.00 $0.18**  **$0.38 $0.55**  **$0.00 $0.04**  **$0.03**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.43**  **$1.43 $0.82**  **$0.14 $0.28**  **$1.24 $0.01**  **$0.08 $0.07**  **$0.28 $0.28**  **$0.00 $0.08**  **$0.16 $0.24**  **$0.00 $0.02**  **$0.01 $1.10**  **$1.10 $0.53**  **$0.14 $0.28**  **$0.95 $0.00**  **$0.06 $0.06** 

**$4.94 $4.94**  **$3.75 $0.18**  **$0.35 $4.27**  **$0.02 $0.28**  **$0.26**

**$0.43 $0.43**  **$0.06 $0.11**  **$0.21 $0.37**  **$0.00 $0.02**  **$0.02 $0.20**  **$0.20 $0.00**  **$0.06 $0.12**  **$0.17 $0.00**  **$0.01 $0.01**  **$0.37 $0.37**  **$0.01 $0.11**  **$0.21 $0.32**  **$0.00 $0.02**  **$0.02**

**$1.00 $1.00**  **$0.00 $0.19**  **$0.68 $0.87**  **$0.00 $0.06**  **$0.05**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$2.09 $4.18**  **$0.11 $0.39**  **$3.13 $3.62**  **$0.02 $0.24**  **$0.22**

**$0.28 $0.57**  **$0.00 $0.20**  **$0.30 $0.49**  **$0.00 $0.03**  **$0.03**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.67**  **$1.67 $1.41**  **$0.02 $0.02**  **$1.45 $0.01**  **$0.09 $0.09**  **$1.27 $1.27**  **$0.00 $0.63**  **$0.47 $1.10**  **$0.01 $0.07**  **$0.07 $0.98**  **$0.98 $0.00**  **$0.20 $0.65**  **$0.84 $0.00**  **$0.05 $0.05**  **$0.69 $0.69**  **$0.00 $0.18**  **$0.42 $0.60**  **$0.00 $0.04**  **$0.04**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $3.34**  **$3.34 $1.10**  **$0.30 $1.95**  **$3.34 $0.00**  **$0.00 $0.00** 
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $1.88**  **$1.88 $0.00**  **$0.63 $1.25**  **$1.88 $0.00**  **$0.00 $0.00** 
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

# $1.10 **$1.10 $1.10**  **$0.00 $0.00**  **$1.10 $0.00**  **$0.00 $0.00** 

**$0.19 $0.19**  **$0.16 $0.00**  **$0.00 $0.16**  **$0.00 $0.01**  **$0.01 $1.88**  **$1.88 $1.63**  **$0.00 $0.00**  **$1.63 $0.01**  **$0.11 $0.10** 
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $2.31**  **$2.31 $2.00**  **$0.00 $0.00**  **$2.00 $0.01**  **$0.13 $0.12**  **$1.16 $1.16**  **$1.00 $0.00**  **$0.00 $1.00**  **$0.01 $0.07**  **$0.06**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**#N/A $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

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

**Price Net, End Item** 



# $0.00 **$0.02 $0.02**  **$0.02 $0.00**  **$0.02 $0.02**  **$0.02 $0.00**  **$1.13 $1.13**  **$1.13 $0.00**  **$1.13 $1.13**  **$1.13 $0.00**  **$0.59 $0.59**  **$0.59 $0.00**  **$0.58 $0.58**  **$0.58 $0.00**  **$0.05 $0.05**  **$0.05 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.02 $0.02**  **$0.02 $0.00**  **$0.02 $0.02**  **$0.02 $0.00**  **$1.13 $1.13**  **$1.13 $0.00**  **$1.13 $1.13**  **$1.13 $0.00**  **$0.59 $0.59**  **$0.59 $0.00**  **$0.58 $0.58**  **$0.58 $0.00**  **$0.05 $0.05**  **$0.05 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.95 $1.95**  **$1.95 $0.00**  **$1.95 $1.95**  **$1.95 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$9.00 $9.00**  **$9.00 $0.00**  **$9.00 $9.00**  **$9.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.20 $1.20**  **$1.20 $0.00**  **$1.20 $1.20**  **$1.20 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit**

**$58.87 $12.23**  **$36.26 $107.36**  **$0.33 $4.50**  **$4.04**

**$117.76**

**$117.76 3**  **1**



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

# $110.80 **$0 $0** 

**Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $110.80**  

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

# 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 )** 



# $0.09 **$0.59 $0.09**  **$0.59 $0.00**  **$0.00 $0.03**  **$0.16 $0.03**  **$0.16 $0.00**  **$0.00 $0.00**  **$0.00** 

# Mark-up Cost **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00** 

**$0.06 $0.39** 

**$0.03 $0.20** 

**$0.02 $0.10** 

**$0.03 $0.21** 

**$0.02 $0.10** 

**$0.00 $0.00**  **$0.00 $0.19**  **$0.01 $0.09**  **$0.00 $0.00**  **$0.00 $0.17**  **$0.01 $0.08**  **$0.00 $0.00**  **$0.03 $0.19**  **$0.01 $0.04**  **$0.02 $0.15** 

**$0.11 $0.66** 

**$0.01 $0.06**  **$0.00 $0.03** 

# $0.01 **$0.05**

**$0.02 $0.13** 

**$0.00 $0.00** 

**$0.09 $0.56** 

**$0.01 $0.08** 

**$0.00 $0.00**  **$0.04 $0.22**  **$0.03 $0.17**  **$0.02 $0.13**  **$0.02 $0.09**  **$0.00 $0.00** 

**$0.06 $0.39** 

**$0.03 $0.20** 

**$0.02 $0.10** 

**$0.03 $0.21** 

**$0.02 $0.10** 

**$0.00 $0.00**  **$0.00 $0.19**  **$0.01 $0.09**  **$0.00 $0.00**  **$0.00 $0.17**  **$0.01 $0.08**  **$0.00 $0.00**  **$0.03 $0.19**  **$0.01 $0.04**  **$0.02 $0.15** 

**$0.11 $0.66** 

**$0.01 $0.06**  **$0.00 $0.03**  **$0.01 $0.05** 

**$0.02 $0.13** 

**$0.00 $0.00** 

**$0.09 $0.56** 

**$0.01 $0.08** 

**$0.00 $0.00**  **$0.04 $0.22**  **$0.03 $0.17**  **$0.02 $0.13**  **$0.02 $0.09**  **$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 $0.03**  **$0.04 $0.25**  **$0.00 $0.00**  **$0.05 $0.31**  **$0.03 $0.16**  **$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** 

**ED&T Mark-up** 

**Total**
**$1.53 $10.40** 

**$117.76 2** 



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

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

# Process & Equipment Assumptions **Process Information**

Large press with auto feed of blanks with auto transfer to induction heating unit.

Large turning and drilling maching with at least 2 stations, auto feed and transfer between stations and means for gun drilling. Operations are ballanced such that the critical path operation is less than 31 sec. Broach machine with auto feeder (orientation and staging) for IP parts.

Large press with auto feed of blanks with auto transfer to induction heating unit.

Large turning and drilling maching with at least 2 stations, auto feed and transfer between stations and means for gun drilling. Operations are ballanced such that the critical path operation is less than 31 sec.

Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper. Hopper feed w/auto orientation and fixture to cam and brake bending machine. Finished part drops into hopper Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper. Hopper feed w/auto orientation and fixture to cam bending machine. Robot to pick IP part from bender and place in paint booth fixture Second robot to spay on wear material. Finished part drops into hopper Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper. Hopper feed w/auto orientation and fixture to cam and brake bending machine. Finished part drops into hopper

# Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper.

Wo rk cell with two movable fixture stations and two multi-axis welding robots. Each joint weld is 3 seconds based on a rate of 56.5 in./min from the machinery handbook. Step1 operator loads parts 1 thru 4, Step2 operator activates clamp and starts process

Medium cylinder cutting machine with auto feed into and out of machine. Machining cell with automatic work feed, tool change, part manipulation and IP part dropped into pack for further processing. Grinding machine with offset polishing wheels, shaker trough to auto feed work and drop IP work into a hopper. Batch clean, plate, paint and cure process (anodize)

Large press with auto feed of blanks with auto transfer to induction heating unit.

Large turning and drilling maching with at least 2 stations, auto feed and transfer between stations and means for gun drilling. Operations are ballanced such that the critical path operation is less than 31 sec. Broach machine with auto feeder (orientation and staging) for IP parts.

Large press with auto feed of blanks with auto transfer to induction heating unit.

Large turning and drilling maching with at least 2 stations, auto feed and transfer between stations and means for gun drilling. Operations are ballanced such that the critical path operation is less than 31 sec.

Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper. Hopper feed w/auto orientation and fixture to cam and brake bending machine. Finished part drops into hopper Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper. Hopper feed w/auto orientation and fixture to cam bending machine. Robot to pick IP part from bender and place in paint booth fixture Second robot to spay on wear material. Finished part drops into hopper Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper. Hopper feed w/auto orientation and fixture to cam and brake bending machine. Finished part drops into hopper Large press with auto feed of sheet or roll stock. IP parts drop in chute to hopper.
Wo rk cell with two movable fixture stations and two multi-axis welding robots. Each joint weld is 3 seconds based on a rate of 56.5 in./min from the machinery handbook. Step1 operator loads parts 1 thru 4, Step2 operator activates clamp and starts process

Medium cylinder cutting machine with auto feed into and out of machine. Machining cell with automatic work feed, tool change, part manipulation and IP part dropped into pack for further processing. Grinding machine with offset polishing wheels, shaker trough to auto feed work and drop IP work into a hopper. Batch clean, plate, paint and cure process (anodize)

# Tooling/Fixturing 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** 



# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113**
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  

# Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  Custom dies x3; front form, back form and trim cut. **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

Custom fixtures **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

Custom fixtures and pot broach **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  Custom dies x3; front form, back form and trim cut. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

Custom fixtures **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom fixtures for bending machine **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

Custom fixtures for bending machine **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom fixtures for bending machine **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

# Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

No tooling, custom fixture nests w/some magnetic clamping. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

**5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  Custom fixture **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom fixtures. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  N/A **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  N/A **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  Custom dies x3; front form, back form and trim cut. **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

Custom fixtures **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

Custom fixtures and pot broach **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  Custom dies x3; front form, back form and trim cut. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

Custom fixtures **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom fixtures for bending machine **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

Custom fixtures for bending machine **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom fixtures for bending machine **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom dies for pattern cuts **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  No tooling, custom fixture nests w/some magnetic clamping. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

**5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  Custom fixture **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  Custom fixtures. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  N/A **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  N/A **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113**
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 
**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** 

**5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0** **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 i** **t 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 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**



# 31.96

- - 1 85 **1.0 3.0**  **127 28.33**  3.00
**31.96**

- - 1 85 **1.0 3.0**  **127 28.33**  3.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 2 45 **1.0 1.0**  **160 22.50**  1.00
**31.96**

- - 2 45 **1.0 1.0**  **160 22.50**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- 

# Minimum Calculated Cycles Time **Project Process Requirement**

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**15.98**

- - 1 20 **1.0 2.0**  **360 10.00**  2.00

**15.98**

- - 1 25 **1.0 2.0**  **288 12.50**  1.00

**15.98**

- - 1 10 **1.0 1.0**  **360 10.00**  1.00

**31.96**

- - 1 18 **1.0 1.0**  **200 18.00**  1.00

**31.96**

- - 1 22 **1.0 1.0**  **164 22.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 15 **1.0 1.0**  **240 15.00**  1.00
**31.96**

- - 1 20 **1.0 1.0**  **180 20.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 15 **1.0 1.0**  **240 15.00**  1.00
**31.96**

- - 1 18 **1.0 1.0**  **200 18.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 12 **1.0 1.0**  **300 12.00**  1.00
**31.96**

- - 1 7 **1.0 1.0**  **514 7.00**  1.00
**31.96**

- - 1 12 **1.0 1.0**  **300 12.00**  1.00

**31.96**

- - 1 15 **1.0 1.0**  **240 15.00**  1.00

**31.96**

- - 1 9 **1.0 1.0**  **400 9.00**  1.00
**31.96**

- - 1 5 **1.0 1.0**  **720 5.00**  1.00

# 31.96

- - 1 9 **1.0 1.0**  **400 9.00**  1.00

**31.96**

- - 2 39 **1.0 1.0**  **185 19.50**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**15.98**

- - 1 16 **1.0 1.0**  **225 16.00**  1.00

**15.98**

- - 1 10 **1.0 1.0**  **360 10.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 1 **1.0 1.0**  **3600 1.00**  1.00
**31.96**

- - 1 32 **1.0 1.0**  **113 32.00**  2.00
**31.96**

- - 1 20 **1.0 1.0**  **180 20.00**  1.00
**31.96**

- - 2,260 27,120 **1.0 1.0**  **300 12.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**15.98**

- - 1 20 **1.0 1.0**  **180 20.00**  1.00

**15.98**

- - 1 25 **1.0 2.0**  **288 12.50**  1.00

**15.98**

- - 1 10 **1.0 1.0**  **360 10.00**  1.00

**31.96**

- - 1 18 **1.0 1.0**  **200 18.00**  1.00

**31.96**

- - 1 22 **1.0 1.0**  **164 22.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 15 **1.0 1.0**  **240 15.00**  1.00
**31.96**

- - 1 20 **1.0 1.0**  **180 20.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 15 **1.0 1.0**  **240 15.00**  1.00
**31.96**

- - 1 18 **1.0 1.0**  **200 18.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 12 **1.0 1.0**  **300 12.00**  1.00
**31.96**

- - 1 7 **1.0 1.0**  **514 7.00**  1.00
**31.96**

- - 1 12 **1.0 1.0**  **300 12.00**  1.00

**31.96**

- - 1 15 **1.0 1.0**  **240 15.00**  1.00

**31.96**

- - 1 9 **1.0 1.0**  **400 9.00**  1.00
**31.96**

- - 1 5 **1.0 1.0**  **720 5.00**  1.00
**31.96**

- - 1 9 **1.0 1.0**  **400 9.00**  1.00

**31.96**

- - 2 39 **1.0 1.0**  **185 19.50**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**15.98**

- - 1 16 **1.0 1.0**  **225 16.00**  1.00

**15.98**

- - 1 10 **1.0 1.0**  **360 10.00**  1.00

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 1 **1.0 1.0**  **3600 1.00**  1.00
**31.96**

- - 1 32 **1.0 1.0**  **113 32.00**  2.00
**31.96**

- - 1 20 **1.0 1.0**  **180 20.00**  1.00
**31.96**

- - 2,260 27,120 **1.0 1.0**  **300 12.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 30 **1.0 1.0**  **120 30.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 60 **1.0 2.0**  **120 30.00**  2.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

# 31.96

- - 1 1 **1.0 1.0**  **3600 1.00**  1.00

**31.96**

- - 1 1 **1.0 1.0**  **3600 1.00**  1.00
**31.96**

- - 1 1 **1.0 1.0**  **3600 1.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **31.96**

- - 1 1 **1.0 1.0**  **3600 1.00**  1.00
**31.96**

- - 1 1 **1.0 1.0**  **3600 1.00**  1.00 **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

**#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

- **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

-

# Technology **Level: Vehicle Class:**  **Study Case#:**  **Sy stem Description:**  **Component Description: Component Quote Level:** 

**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**



# A 

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

1 OEM Transmission Assembly **1**

2 **0**
3 **0**
4 **0** 

# B 

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

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



# GENERAL COMPONENT INFORMATION

3 **0**
4 **0**
5 **0**
6 **0**
7 **0**
8 **0**
9 **0**
10 **0** 

# C 

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

1 **0**

2 **0**
3 **0**

4 **0**

5 **0**



# D 

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

1 Misc Fasteners **1**

2 **0**
3 **0**

4 **0**

# 5 **0**

6 **0**

7 **0**
8 **0**
9 **0**
10 **0**

11 **0**

12 **0**
13 **0**

14 **0**
15 **0**



# 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 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, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote Cost per 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

# 6 Speed DCT vs 8 Speed DCT Transmission

**6-8 Speed DCT Transmission**
**Gears**
OEM Transmission Assembly

**Primary Process Description OEM/Supplier Classification**  **Material Specification**  **Labor**

**Classification**



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

Assemble added components (gears, synchronizers, etc) OEM Transmission Assembly Not Applicable General Assembly-OEM 

# GENERAL MANUFACTURING INFORMATION



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

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

S

# 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 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, Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 6 Layers of 8 on single Pallet Base. Cost per Tote: $75/Tote Cost per 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

# OEM Operating Pattern (W eeks/Year): Annual Engine Volume (CPV): Components per Engine: Annual Component Volume: **Part Number:** We ekly Component Volume:
Estimated Product Life:

**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 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** 

Transmission Assembly, OEM, MHC **120 4**  **4 1**  0.000 **$0.00 $83.31**  **$75.00 $300.00**  **$0.00 $2.78** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**#DIV/0! 0**  **1 1**  2.400 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 



# MANUFACTURING RATES **MANUFACTURING COSTS**

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 
**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

**#DIV/0! 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A** 

# Material **Labor**

**T1 or OEM Total Manufacturing Cost: $0.15**  **$2.78**

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

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

----- **Base Cost Impact to Vehicle: $0.15**  **$2.78**



# PACKAGING **CALCULATIONS:** Packaging Type: Part Size: Parts/Layer: Number of Layers: **Cost per Piece**  **Total Amount**  **Lump Sum**

**Payment (%) Total # of** 

**Pieces Number of** 

**Months**



# Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 4,500,000**  **60**

**Cost per Piece Tier Pad Price**  **Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack**



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

# Packaging Cost Total: **$0.000** 

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

# OEM Plant Location: Supplier Plant Location: OEM/T1 Classification: **Not Applicable** 

# Shipping Method: Packaging Specification: **NA**

**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 "** 



# $2.50 **$5.28 0.00%**  **0.00% 0.00%**  **0.00% 0.00%**  **$0.00 $5.28**  **$5.28**

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  

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

**10**

**MANUFACTURING COSTS MARK-UP COSTS**  **TOTAL COSTS TOOLING & INVESTMENT** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 
**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 

**#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00** 

**Supplier Account Cost**  **Purchase Price/**

**Unit Purchase** 

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

**Price Net, End Item** 



# $0.00 $0.15 **$0.00 $0.15**  **$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**  **$0.00** $0.00 **$0.00 $0.00** 

**Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up $5.43** 

**$2.50 $5.43**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $5.43** 

----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

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

**$2.50 $5.43**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $5.43**  **$0 $0** 
**Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $5.43** **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** **/ 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** **)** 

### 3 **1**



## 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** **)**



# 5.00% $0 **250** 1 **6 57447** 

**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**



# $0.00 0 $0.00 0 $0.00 0

# Material **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 )** 



# $0.00 **$2.78 $2.50**  **$5.28 $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**  

# Costs Broken Out Into Categories with Quantity per Assembly Taken into Account **Manufacturing Cost Mark-up Cost** 

**$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**  **$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 $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**

**$0.15 $0.15**  **$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** 

**Material Labor**  **Burden TMC**  **Scrape SG&A**  **Profit ED&T**  **Mark-up Total** 
**$0.15 $2.78**  **$2.50 $5.43**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$5.43 2** 



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

# Process & Equipment Assumptions **Tooling/Fixturing and Gauge Assumptions**  **Days/ Week** 

**5**

**5**
**5**
**5**

**5**
**5** 

# Process Information

**5**
**5**
**5**
**5**
**5**
**5**
**5**
**5**

**5**

**5**

**5**

**5**

**5**

# 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 "** 



# 2 **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1 120

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - 

# MANUFACTURING ASSUMPTIONS **Minimum Calculated Cycles Time Project Process Requirement**  **Projected Operating Pattern**

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - -

**2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

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-

### Page: 1 of 12 

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

## Technology Level: **5 Speed Versus 6 Speed Transmission** 

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

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class)**  

## Components per Transmission: OEM/T1 Classification: **System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  **02 -N0802-** ** 

## We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life:

**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 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**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810e70cd.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: **5 Speed Versus 6 Speed Transmission** 

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

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class)**  

## Components per Transmission: OEM/T1 Classification: **System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  **02 -N0802-** ** 

## We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life:

**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 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)**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810e70cd.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: **5 Speed Versus 6 Speed Transmission** 

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

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class)**  

## Components per Transmission: OEM/T1 Classification: **System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  **02 -N0802-** ** 

## We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life:

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

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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



### D 

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

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

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

**Price Net, End Item** 

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

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

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly. 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.00**

**T1 or OEM Total Manufacturing Cost: $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

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

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A 

### Supplier for Subassembly.

**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:** 

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**Base Cost Impact to Vehicle: $0.00**  **$0.00 $0.00**  **$0.00 #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0**  **$0**
**Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: #N/A**  **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810e70cd.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: **5 Speed Versus 6 Speed Transmission** 

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

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0802 (N>New Technology Package, 08>Technology Level, 02>Vehilce Class)**  

## Components per Transmission: OEM/T1 Classification: **System Description: 2007-2009 Toyota Camry, 6 Speed Automatic Transmission**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  **02 -N0802-** ** 

## We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life:

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

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

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

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

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

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

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

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

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

**Pads Pallet/Rack** 



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

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

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

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e70cd.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**  

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



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



### File:09000064810e70cd.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 12 

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

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

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



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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

- - - - **1.0 1.0** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



### File:09000064810e70cd.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 7 of 12 

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

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

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



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

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

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

**$0.00 2** 



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



### File:09000064810e70cd.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**  

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

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# 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** 

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-



## Purchase Part - High Impact Item (Full Cost Mapping) **#DIV/0! #DIV/0!** 

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

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### File:09000064810e70cd.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 10 of 12 

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

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

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

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

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

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

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

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

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

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

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### Page: 11 of 12 

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

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

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database)**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:09000064810e70cd.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:09000064810e70cd.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411