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 PUMP & 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)

Item

Subsystem

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

Item

Subsystem

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 PUMP & 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 PUMP & 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

Item

Subsystem

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
SUBSYSTEM ROLL-UP $ 74.82 $ 21.77 $ 91.16 $ 187.74 $ 0.33 $ 4.50 $ 4.04 $ 1.53 $ 10.40 $ - $ 198.14
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 Reverse 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 Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

S

Assembly) ubassembly

Component

Sub-Subsystem

Investment

(X1000)

Tooling 

(x1000)

Markup

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/

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)

Item

Subsystem

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 Reverse 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 Valve 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 Valve 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 Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

S

Assembly) ubassembly

Component

Sub-Subsystem

Investment

(X1000)

Tooling 

(x1000)

Markup

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/

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)

Item

Subsystem

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#:

System Description: 6-8 Speed DCT Transmission

Component Description: Gears

Component Quote Level: 01 Gearing (Input & Output)

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

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 & Weld 

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 A

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. Sam

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"(300

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 
CT vs 8 Speed DCT Transmission

DCT Transmission

Part Number:

 (Input & Output)

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

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 & Weld 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

 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:

122cm)x45"(114cm)x34"(86cm)

200 US funds (Mike S.)

tic Returnables Last 5 Years

uum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 

Pallet Base $100/Base

Tier Pad $40/Pad

aller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

ayers of 8 on single Pallet Base.

er Pads for Option 1 Pallets $1.00/Pad (Mike S.)

vider Pads for Option 1 Pallet $3.00/Pad (Mike S.)
vider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

 Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

ividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00
OEM Operating Pattern (Weeks/Year):

Annual Engine Volume (CPV):

Components per Engine:

Annual Component Volume:

Weekly Component Volume:

Estimated Product Life:

Parallel Processing

Mutiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

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

dable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

ULATIONS: 

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 Markup RateTotal Markup Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 Quantit

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 th

Net Cost Impact to Vehicle: $57.48

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

1 6 57447

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

$0.00 0

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

$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

en 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

 & 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.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

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

Projected Operating Pattern Minimum Calculated Cycles Time Project Process Requirement

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! - - - -


Mulitplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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#:

System Description: 6-8 Speed DCT Transmission

Component Description: Gears

Component Quote Level: 02 Shafting

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

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 A

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. Sam

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"(300

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 
CT vs 8 Speed DCT Transmission

DCT Transmission

Part Number:

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

#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

 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:

122cm)x45"(114cm)x34"(86cm)

200 US funds (Mike S.)

tic Returnables Last 5 Years

uum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 

Pallet Base $100/Base

Tier Pad $40/Pad

aller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

ayers of 8 on single Pallet Base.
er Pads for Option 1 Pallets $1.00/Pad (Mike S.)

vider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

 Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

ividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00
OEM Operating Pattern (Weeks/Year):

Annual Engine Volume (CPV):

Components per Engine:

Annual Component Volume:

Weekly Component Volume:

Estimated Product Life:

Parallel Processing

Mutiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

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: &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.00 $0.00

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

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

dable 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

ATIONS: 

OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: Not Applicable

Shipping Method:

Packaging Specification: NA

ED&T/ 

R&D 

Rate

(DB)

Total Markup RateTotal Markup Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 p

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 

$0.00 $0.00

$0.00 $0.00 $6.56 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $6.56

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

6 57447

Other #3 Pads 

Pallet/Rack

0

Notes: 

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00

$0.00 $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

en 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

 & 3 must  & 3 must all equal same all equal same value otherwise otherwise there is a computation 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
555

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

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! - - - -

Projected Operating Pattern Minimum Calculated Cycles Time Project Process Require

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 47000 #DIV/0! 85%0 #DIV/0! 

- - - -

2 10 100 47 47000 #DIV/0! 85%0 #DIV/0! 

- - - -

Mulitplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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#:

System Description: 6-8 Speed DCT Transmission

Component Description: Gears

Component Quote Level: 03 Housing / Case

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

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 A

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. Sam

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"(300

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 

CT vs 8 Speed DCT Transmission

DCT Transmission

Part Number:

OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Mutiplier

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

 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:

122cm)x45"(114cm)x34"(86cm)

200 US funds (Mike S.)

tic Returnables Last 5 Years

uum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 

Pallet Base $100/Base

Tier Pad $40/Pad

aller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

ayers of 8 on single Pallet Base.

er Pads for Option 1 Pallets $1.00/Pad (Mike S.)

vider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

 Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

ividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

OEM Operating Pattern (Weeks/Year):

Annual Engine Volume (CPV):

Components per Engine:

Annual Component Volume:

Weekly Component Volume: Packaging Spe

Estimated Product Life:

Material Usage "lbs"

Material 

Cost $/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden Rate

$/Hour

(DB)

Applied 

Burden Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

nvestment 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

Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00

ckaging 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 Markup RateTotal Markup Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

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 Ass

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 com

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

6 57447

Other #3 

Pads 

Pallet/Rack

0

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

o 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

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.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs./ Hr.

@

Stated Efficiency

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

Projected Operating Pattern Minimum Calculated Cycles Time 

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


Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Mulitplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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! -

ulated 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#:

System Description:

Component Description:

Component Quote Level:

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

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 Assemblies10

18 7th Spd Gear Shift Fork Piston Asm 

(includes Cylinder Liners)

2

19 7th Spd Gear Shift Fork Piston Asm 

(includes Cylinder Liners)

20

20 7th Spd Spool Valve1

21 7th Spd Spool Valve1

22 7th Spd Spool Valve1

23 7th Spd Spool Valve10

24 8th Spd Gear Synchronizer2

25 8th Spd Gear Synchronizer2

26 8th Spd Gear Synchronizer2

27 8th Spd Gear Synchronizer1

28 8th Spd Gear Synchronizer10

29 8th Spd Gear Hub, Shift Collar1

30 8th Spd Gear Hub, Shift Collar10

31 8th Spd Gear Shift Hub1

32 8th Spd Gear Shift Hub10

33 8th Spd Gear Shift Fork Assemblies1

34 8th Spd Gear Shift Fork Assemblies1

35 8th Spd Gear Shift Fork Assemblies1

36 8th Spd Gear Shift Fork Assemblies1

37 8th Spd Gear Shift Fork Assemblies1

38 8th Spd Gear Shift Fork Assemblies1

39 8th Spd Gear Shift Fork Assemblies1

40 8th Spd Gear Shift Fork Assemblies10

41 8th Spd Gear Shift Fork Piston Asm 

(includes Cylinder Liners)

2

42 8th Spd Gear Shift Fork Piston Asm 

(includes Cylinder Liners)

20

43 8th Spd Spool Valve1

44 8th Spd Spool Valve1

45 8th Spd Spool Valve1

46 8th Spd Spool Valve100

Modified Components:0

47 Valve Body10

48 Valve Body Asm10
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 A

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. Sam

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"(300

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

l 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 WC2, 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

Weld 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 WC2, 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

Weld 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
Worm 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

ing = Processed Raw Material Estimate + Actual Component Assembly Process)

hase 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 Suppli

"SAC"=(Supplier Accounted Costs) 

for Final or Sub-Assembly. In addit

quote sheet. Thus component cost 

"Alpha-Numeric Character" = Indica

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 

Part Number:

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Mutiplier

Material Usage "lbs"

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

=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

C"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM 

Assembly. In addition component material cost is accounted for in T1 

te 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 (Weeks/Year): OEM Plant Location:

Annual Engine Volume (CPV): Supplier Plant Location:

Components per Engine: OEM/T1 Classification:

Annual Component Volume: Shipping Method:

Weekly Component Volume: Packaging Specification:

Estimated Product Life:

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate $/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total Markup RateTotal Markup 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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

$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

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

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&TR&D

Total Markup Cost

(Component/ Assembly)

$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

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

computation error.
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.

Work 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.

Work 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.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs./ Hr.

@

Stated Efficiency

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

Projected Operating Pattern Minimum Calculated Cycles Time 

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

52 10 100 47 4700 96 37.60 85% 113

52 10 100 47 4700 96 37.60 85% 113

52 10 100 47 47000 #DIV/0! 85%0

52 10 100 47 4700 96 37.60 85% 113

52 10 100 47 4700 96 37.60 85% 113

52 10 100 47 47000 #DIV/0! 85%0

52 10 100 47 47000 #DIV/0! 85%0

52 10 100 47 47000 #DIV/0! 85%0

52 10 100 47 47000 #DIV/0! 85%0

52 10 100 47 47000 #DIV/0! 85%0

52 10 100 47 47000 #DIV/0! 85%0

52 10 100 47 47000 #DIV/0! 85%0

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Mulitplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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! -

ulated 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#:

System Description:

Component Description:

Component Quote Level:

Item 

Reference #

Part Description Part Number

Q

T

Y Per Assembly

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 A

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. Sam

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. Sam

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"(300

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

l Cost mapping)

Assemble added components (gears, 

synchronizers, etc) OEM Transmission Assembly Not Applicable General Assembly-OEM

GENERAL MANUFACTURING INFORMATION

ing = Processed Raw Material Estimate + Actual Component Assembly Process)

hase 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 (Weeks/Year):

Annual Engine Volume (CPV):

Components per Engine:

Annual Component Volume:

Part Number: Weekly Component Volume:

Estimated Product Life:

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Mutiplier

Material Usage "lbs"

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

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total Markup RateTotal Markup Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

$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

ANUFACTURING 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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

3

1

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

$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.

Pcs./ Hr. (100% Eff.)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs./ Hr.

@

Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

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

Projected Operating Pattern Minimum Calculated Cycles Time Project Process Requirement

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! - - - -

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

Mulitplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

1.0 4.0 120 30.00 4.00

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! -

Project Process Requirement

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! -

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

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 (Weeks/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-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 (Weeks/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-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 (Weeks/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-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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 SubAssembly.

"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: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- #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 a

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 (Weeks/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-** Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Manufacturing Costs 

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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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 Gross Mark-up Costs x Quantity Process Information Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Minimum Calculated Cycles Time Project Process Requirement

File:09000064810e70cd.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File: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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e70cd.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

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)

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e70cd.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411