### Page:1 of 15 

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

DRAFT

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



# 060600 Brake A **ctuation Subsy stem** 

1 **00 Vehicle Installation of Brake Actuation Subsystem**  **0.20 $**  **0.89**

**$ 0.14** 

**$ 1.23** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 1.23** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.30** 

**$ 1.22** 

**$ 0.19** 

**$ 1.71** 

**$**



### 2 **01 Master Cylinder and Reservoir** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 3 **02 Pedals**  **39.43 $**  **14.02**

**$ 19.25** 

**$ 72.71** 

**$ 0.98** 

**$ 8.22** 

**$ 6.87** 

**$ 2.02** 

**$ 18.09** 

**$ 0.22** 

**$ 91.02** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 5.44** 

**$ 1.84** 

**$ 5.97** 

**$ 13.25** 

**$**



### 4 **03 Brake Lines and Hoses** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.89** 

**$ 0.38** 

**$ 1.28** 

**$ 2.55** 

**$**



### 5 **05 Brake Control Valves** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Manufacturing **Total Manufacturing** 

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

### Sub-Subsystem Description 

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

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

### System

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

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

6 **06 Brake Fluid** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **60 Wiring Harness Connections**  **2.60 $**  **1.82**

**$ 0.78** 

**$ 5.19** 

**$ 0.03** 

**$ 0.34** 

**$ 0.31** 

**$ 0.13** 

**$ 0.81** 

**$ 0.06** 

**$ 6.06** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 10 **75 Brackets**  **0.78 $**  **0.07**

**$ 0.55** 

**$ 1.40** 

**$ 0.00** 

**$ 0.08** 

**$ 0.06** 

**$ 0.01** 

**$ 0.16** 

**$ 0.01** 

**$ 1.56** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous**  **0.45 $**  **0.20**

**$ 0.45** 

**$ 1.10** 

**$ 0.00** 

**$ 0.07** 

**$ 0.04** 

**$ 0.03** 

**$ 0.14** 

**$ 0.01** 

**$ 1.25** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.50** 

**$**

**-**

**$**

**-**

**$ 0.50** 

**$**



### 43.46 **$ 17.00** 

**$ 21.17** 

**$ 81.63** 

**$ 1.02** 

**$ 8.71** 

**$ 7.29** 

**$ 2.19** 

**$ 19.20** 

**$ 0.29** 

**$ 101.12** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 7.13

**$ 3.44** 

**$ 7.43** 

**$ 18.01** 

**$ SUBSYSTEM ROLL-UP** 

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

### Page:2 of 15 

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

DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Manufacturing **Total Manufacturing** 

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

### Sub-Subsystem Description 

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

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

### System

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

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

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

### Page:3 of 15 

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

DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Manufacturing **Total Manufacturing** 

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

### Sub-Subsystem Description 

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

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

### System

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

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

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

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATION

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **Net**

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

# BASE
**TECHNO**
**LOGY**

Manufacturing **Total Manufacturing** 

**Cost (Component/**  

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem



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



# 05 **Cy linder Blocks** 

A1 **01**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

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**$**

-

$

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$

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### 2

- $

-

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$

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$

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$

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$

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**-**

**$**



### -

$

-

$

-

$

**-**

**$**

B1 **02**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

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### 2

- $

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$

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-

$

-

$

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$

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$

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$

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**$**

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**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

C1 **03**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

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**$**

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$

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$

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### 2

- $

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### -

$

-

$

-

$

**-**

**$**

D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

- $

-

$

-

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



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

**- $** 

**-**

**$**

**-**

**$** 

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

E1 **65**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

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**$**

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$

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### 2

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**-**

**$**

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**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

F1 **66**

- $

-

$

-

$

**-**

**$**

-

$

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$

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$

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### 2

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### -

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**$**

G1 **67**

- $

-

$

-

$

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**$**

-

$

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$

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$

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$

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### 2

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### -

$

-

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**-**

**$**

H1 **70**

- $

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$

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$

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**$**

-

$

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### 2

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### -

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I1 **75**

- $

-

$

-

$

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**$**

-

$

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$

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### -

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J1 **80**

- $

-

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$

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-

$

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### -

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K1 **85**

- $

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### 2

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### -

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L1 **90**

- $

-

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$

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$

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$

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-

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**-**

**$ (x1000)**  **(Component/ Assembly)**  **Assembly) (Component** 

**/ Assembly) Cost Impact to** 

**OEM (Component/**  **Assembly)**SubsystemSub-Subsystem



### L1 **90**

- $

-

$

-

$

**-**

**$**

-

$

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$

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$

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**$**

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### -

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**-**

**$**

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

### Page:4 of 15 

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

DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Manufacturing **Total Manufacturing** 

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

### Sub-Subsystem Description 

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

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

### System

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

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

M1 **99**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### 2

- $

-

$

-

$

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-

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-

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### -

$

-

$

-

$

**-**

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N1 **00**

- $

-

$

-

$

**-**

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-

$

-

$

-

$

-

$

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-

$

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-

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-

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-

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-

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-

$

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### 2

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

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-

$

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### -

$

-

$

-

$

**-**

**$**

**SU**

**BS**

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

**- $** 

**-**

**$**

**-**

**$** 

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



# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total** 

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

### Manufacturing **Total** Markup **Total Markup Total**  **Net**

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



# 05 **Cy linder Blocks** 

A1 **01** 0.20 $ 0.89

$ 0.14

$ **1.23**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.23**

**$**

-

$

-

$

-

$ 0.30

$ 1.22

$ 0.19

$ **1.71**

**$**



### B1 **02**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### C1 **03** 39.43 $ 14.02

$ 19.25

$ **72.71**

**$** 0.98

$ 8.22

$ 6.87

$ 2.02

$ **18.09**

**$** 0.22

$ **91.02**

**$**

-

$

-

$

-

$ 5.44

$ 1.84

$ 5.97

$ **13.25**

**$**



### D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

- $

-

$

-

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



### E1 **65**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### F1 **66**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### G1 **67**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### H1 **70** 2.60 $ 1.82

$ 0.78

$ **5.19**

**$** 0.03

$ 0.34

$ 0.31

$ 0.13

$ **0.81**

**$** 0.06

$ **6.06**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### I1 **75**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### J1 **80** 0.78 $ 0.07

$ 0.55

$ **1.40**

**$** 0.00

$ 0.08

$ 0.06

$ 0.01

$ **0.16**

**$** 0.01

$ **1.56**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### K1 **85**

**- $** 

**- $** 

**- $** 

**- $**  **System**

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

**(x1000) Investment** 

**(X1000) Manufacturing** 

**Cost (Component/**  **Assembly)**ItemSubsystemSub-Subsystem 

### Manufacturing

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

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

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

**Assembly Cost Impact to** 

**OEM**



### K1 **85**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



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

### Page:5 of 15 

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

DRAFT

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

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Manufacturing **Total Manufacturing** 

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

### Sub-Subsystem Description 

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

Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact to** 

**OEM Total Markup** 

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

### System

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

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

L1 **90**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

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### - $

-

$

-

$

**-**

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-

$

-

$

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-

$

**-**

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-

$

**-**

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**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$**

M1 **99**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

$

-

$

**-**

**$**



### N1 **00**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

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



### SU

**BS**

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

**- $** 

**-**

**$**

**-**

**$** 

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

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

### Page:6 of 15 

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

DRAFT



# 060600 Brake A **ctuation Subsy stem** 

1 **00**

2 **01**

3 **02**

4 **03**

5 **05** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### End Item

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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 1.71** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ (0.10)** 

**$ (0.32)** 

**$ (0.05)** 

**$ (0.47)** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ (0.47)** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

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**$**

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**$**

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**-**

**$**

**0.07 $**  **0.95**

**$ 0.85** 

**$ 0.33** 

**$ 2.20** 

**$ 0.10** 

**$ 15.55** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 33.99** 

**$ 12.18** 

**$ 13.28** 

**$ 59.45** 

**$ 0.91** 

**$ 7.27** 

**$ 6.02** 

**$ 1.68** 

**$ 15.89** 

**$ 0.13** 

**$ 75.47** 

**$**

**-**

**$**

**-**

**$**

**0.01 $**  **0.17**

**$ 0.20** 

**$ 0.06** 

**$ 0.44** 

**$**

**-**

**$ 2.99** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ (0.89)** 

**$ (0.38)** 

**$ (1.28)** 

**$ (2.55)** 

**$ (0.01)** 

**$ (0.17)** 

**$ (0.20)** 

**$ (0.06)** 

**$ (0.44)** 

**$**

**-**

**$ (2.99)** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ System** 

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

**(x1000) System** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM**



### 6 **06**

7 **10**

8 **60**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

14 **99 -** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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**-**

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**-**

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**-**

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**-**

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**-**

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**-**

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**$**

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**-**

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**-**

**$**

**-**

**$ 2.60** 

**$ 1.82** 

**$ 0.78** 

**$ 5.19** 

**$ 0.03** 

**$ 0.34** 

**$ 0.31** 

**$ 0.13** 

**$ 0.81** 

**$ 0.06** 

**$ 6.06** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

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**-**

**$ 0.78** 

**$ 0.07** 

**$ 0.55** 

**$ 1.40** 

**$ 0.00** 

**$ 0.08** 

**$ 0.06** 

**$ 0.01** 

**$ 0.16** 

**$ 0.01** 

**$ 1.56** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

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**$ 0.50** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ (0.05)** 

**$ 0.20** 

**$ 0.45** 

**$ 0.60** 

**$ 0.00** 

**$ 0.07** 

**$ 0.04** 

**$ 0.03** 

**$ 0.14** 

**$ 0.01** 

**$ 0.75** 

**$**

**-**

**$**

**-**

**$**



### 0.08 **$ 1.11** 

**$ 1.06** 

**$ 0.40** 

**$ 2.64** 

**$ 0.10** 

**$ 20.75** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 36.33

**$ 13.56** 

**$ 13.74** 

**$ 63.62** 

**$ 0.94** 

**$ 7.59** 

**$ 6.23** 

**$ 1.79** 

**$ 16.55** 

**$ 0.20** 

**$ 80.37** 

**$**

**-**

**$**

**-**

**$**



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

### Page:7 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



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

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

**(x1000) System** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM**



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

### Page:8 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



# BASE
**TECHNO**
**LOGY**ItemSubsystemSub-Subsystem 

### End Item

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

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

**(x1000) System** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM**

End Item SG&A Profit ED&T-R&D **Tooling (x1000)**  Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

**Cost (Component**  **Net**

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

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

# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Investment (X1000)** 



# 05 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2

E1 **65**

2

F1 **66**

2

G1 **67**

2

H1 **70**

2

I1 **75**

2

J1 **80**

2

K1 **85**

2

L1 **90**SubsystemSub-Subsystem



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

- $

-

$

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- $

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**- $** 

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**/ Assembly) Cost Impact to** 

**OEM (x1000)** 



### L1 **90**

2 -

$

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

### Page:9 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### M1 **99**

2

N1 **00**

2

**SU**

**BS**

**YS**



# TECHNO
**LOGY**
**PACKAG**SubsystemSub-Subsystem 

### End Item

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

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

**(x1000) System** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM**

- $

-

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**-**

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

**- $** 

**-**

**$**

**-**

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# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup **Total Markup Total**  **Net**



# 05 **Cy linder Blocks** 

A1 **01**

B1 **02**

C1 **03**

D1 **04**

E1 **65**

F1 **66**

G1 **67**

H1 **70**

I1 **75**

J1 **80**

K1 **85**ItemSubsystemSub-Subsystem



### End Item

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

- $

-

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-

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**-**

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$ **1.71**

**$**

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0.07 $ 0.95

$ 0.85

$ 0.33

$ **2.20**

**$** 0.10

$ **15.55**

**$**

-

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-

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

- $

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**- $**  **Total Markup**

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

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

**Assembly Cost Impact to** 

**OEM System** 

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



### K1 **85**

-

$

-

$

-

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-

$

**-**

**$**

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**-**

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-

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-

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

### Page:10 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### L1 **90**

M1 **99**

N1 **00**

**SU**

**BS**

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

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

**(x1000) System** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

Markup **Total Markup**

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total Manufacturing** 

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM**

- $

-

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**-**

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



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



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

### Page:11 of 15 

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

DRAFT



# 060600 Brake A **ctuation Subsy stem** 

1 **00**

2 **01**

3 **02**

4 **03**

5 **05** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### -

**$**

**- $** 

**- $** 

**- $** 

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



### 6 **06**

7 **10**

8 **60**

9 **70**

10 **75**

11 **80**

12 **85**

13 **90**

14 **99 -** 

**$**

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 



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

### Page:12 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



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



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

### Page:13 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



# BASE
**TECHNO**
**LOGY**ItemSubsystemSub-Subsystem 

### Investment(X1

**000)**



# 05 **Cy linder Blocks** 

A1 **01**

2

B1 **02**

2

C1 **03**

2

D1 **04**

2

E1 **65**

2

F1 **66**

2

G1 **67**

2

H1 **70**

2

I1 **75**

2

J1 **80**

2

K1 **85**

2

L1 **90**SubsystemSub-Subsystem



### L1 **90**

2

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

### Page:14 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### M1 **99**

2

N1 **00**

2

**SU**

**BS**

**YS**



# TECHNO
**LOGY**
**PACKAG**SubsystemSub-Subsystem 

### Investment(X1

**000)**



# 05 **Cy linder Blocks** 

A1 **01**

B1 **02**

C1 **03**

D1 **04**

E1 **65**

F1 **66**

G1 **67**

H1 **70**

I1 **75**

J1 **80**

K1 **85**ItemSubsystemSub-Subsystem



### K1 **85**

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

### Page:15 of 15 

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

DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### L1 **90**

M1 **99**

N1 **00**

**SU**

**BS**

**YS Investment(X1** 

**000)**



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

### Page:1 of 6 

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

DRAFT

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



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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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-

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**-**

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-

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**-**

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**-**

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# 060600 Brake A **ctuation Subsy stem** 

1 **00 Vehicle Installation of Brake Actuation Subsystem**  **0.20 $**  **0.89**

**$ 0.14** 

**$ 1.23** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 1.23** 

**$**

**-**

**$**



### A Vehicle Installation of Brake Actuation Subsystem Components 06 06 00

- N0502

- 01 1 Mod. 1 Additional brake pedal bracket,
fasteners and wire harness connections for Brake-by-wire pedal assembly. 

### 0.20 $ 0.89

$ 0.14

$ **1.23**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.23**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**Sub-Subsystem



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponent 

### System

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

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

# NEW TECHNOLOGY PACKAGE QUOTE
**PARAMETERS**

MarkupAssembly 

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

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

2 **01 Master Cylinder and Reservoir** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A H Master Cylinder 06 06 01

- N0502

- 01 1 na 1 Bore and Stroke Ratios are slightly different between HEV and Base, however it is estimated they would be very similar in cost. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 3 **02 Pedals**  **39.43 $**  **14.02**

**$ 19.25** 

**$ 72.71** 

**$ 0.98** 

**$ 8.22** 

**$ 6.87** 

**$ 2.02** 

**$ 18.09** 

**$ 0.22** 

**$ 91.02** 

**$**

**-**

**$**



### A H Brake Pedal Assembly 06 06 02

- N0502

- 01 1 Full 1 Brake-by-wire versus traditional pedal and bracket assembly brake in

base vehicle. 

### 39.43 $ 14.02

$ 19.25

$ **72.71**

**$** 0.98

$ 8.22

$ 6.87

$ 2.02

$ **18.09**

**$** 0.22

$ **91.02**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 4 **03 Brake Lines and Hoses** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A Brake Line Assembly #1- HCU to Control valve 06 06 03

- N0502

- 01 1 na 1 HEV Part Save - Do not need for HEV as a result of not having Brake
Pressure Control Valve. Costed in Base Brake Actuation System. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B Brake Line Assembly #2- HCU to Control valve 06 06 03

- N0502

- 02 1 na 1 Same as above



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5 **05 Brake Control Valves** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A Brake Pressure Control Valve 06 06 05

- N0502

- 01 1 na 1 HEV able to delete due to regen - braking through front wheels in regen mode. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 6 **06 Brake Fluid** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

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



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



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

### Page:2 of 6 

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

DRAFT

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



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponent 

### System

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

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

# NEW TECHNOLOGY PACKAGE QUOTE
**PARAMETERS**

MarkupAssembly 

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

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 8 **60 Wiring Harness Connections**  **2.60 $**  **1.82**

**$ 0.78** 

**$ 5.19** 

**$ 0.03** 

**$ 0.34** 

**$ 0.31** 

**$ 0.13** 

**$ 0.81** 

**$ 0.06** 

**$ 6.06** 

**$**

**-**

**$**



### A Wire Harness - Solenoid, Brake Pedal Cut-off Value (3 Pins) 

### 06 06 60

- N0502

- 01 1 Full 1 Required for brake-by-wire 

### 0.65 $ 0.45

$ 0.19

$ **1.30**

**$** 0.01

$ 0.08

$ 0.08

$ 0.03

$ **0.20**

**$** 0.02

$ **1.52**

**$**

**-**

**$**



### B Wire Harness - Pressure Sensor, Brake Pedal Cut-off Valve (3 Pins) 

### 06 06 60

- N0502

- 02 1 Full 1 Required for brake-by-wire 

### 0.65 $ 0.45

$ 0.19

$ **1.30**

**$** 0.01

$ 0.08

$ 0.08

$ 0.03

$ **0.20**

**$** 0.02

$ **1.52**

**$**

**-**

**$**



### C Wire Harness - Angle Sensor, Brake Pedal & Bracket Assembly (6 Pins) 

### 06 06 60

- N0502

- 03 1 Full 1 Required for brake-by-wire 

### 1.30 $ 0.91

$ 0.39

$ **2.60**

**$** 0.01

$ 0.17

$ 0.16

$ 0.06

$ **0.40**

**$** 0.02

$ **3.02**

**$**

**-**

**$**



### D Wire Harness - Brakelamp/Redundant Cruise Deact (4 Pins) 

### 06 06 60

- N0502

- 04 1 na 1 Required for both Base and HEV Configuration. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

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



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 10 **75 Brackets**  **0.78 $**  **0.07**

**$ 0.55** 

**$ 1.40** 

**$ 0.00** 

**$ 0.08** 

**$ 0.06** 

**$ 0.01** 

**$ 0.16** 

**$ 0.01** 

**$ 1.56** 

**$**

**-**

**$**



### A Bracket - Brake Pedal 06 06 75

- N0502

- 01 1 Full 1 

### 0.78 $ 0.07

$ 0.55

$ **1.40**

**$** 0.00

$ 0.08

$ 0.06

$ 0.01

$ **0.16**

**$** 0.01

$ **1.56**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A Nut - Pedal & Bracket Assembly Brake to Booster 06 06 80

- N0502

- 01 4 na 1 Required for both Base and HEV Configuration. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B Bolt - Pedal & Bracket Assembly Brake to Int.Cowl Brkt 06 06 80

- N0502

- 02 2 na 1 Required for both Base and HEV Configuration. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### C Bolt - Cowl Int. Brkt to Cowl Brkt. (Same as B) 06 06 80

- N0502

- 03 2 Full 1 Only required for HEV as a result of additional bracket required to install HEV Brake-by-wire pedal module.

**PIA to Vehicle Installation.** 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### D Bolt - Brake Pressure Control Valve 06 06 80

- N0502

- 04 2 na 1 Only required for Base, HEV handles brake loading via regen.

**PIA to Vehicle Installation**

. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous**  **0.45 $**  **0.20**

**$ 0.45** 

**$ 1.10** 

**$ 0.00** 

**$ 0.07** 

**$ 0.04** 

**$ 0.03** 

**$ 0.14** 

**$ 0.01** 

**$ 1.25** 

**$**

**-**

**$**



### A Switch - Brake Lamp and Redundant Cruise Deact 06 06 99

- N0502

- 01 1 na 1 Same for Base and HEV



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**

Upgraded Booster Pin for HEV 

### B Pin - Booster Clevis (Overmolded with anti push-out legs) 06 06 99

- N0502

- 02 1 Full 1 Upgraded Booster Pin for HEV

Estimated Price ≈$1.25 

### 0.45 $ 0.20

$ 0.45

$ **1.10**

**$** 0.00

$ 0.07

$ 0.04

$ 0.03

$ **0.14**

**$** 0.01

$ **1.25**

**$**

**-**

**$**



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

### Page:3 of 6 

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

DRAFT

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



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing** 

**Cost (Component/**  **Assembly)**SubassemblyComponent 

### System

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

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

# NEW TECHNOLOGY PACKAGE QUOTE
**PARAMETERS**

MarkupAssembly 

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

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

**Cost (Component/**  **Assembly) Total** 

**Packaging**

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

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

**OEM** 

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

C Clip - Pin, Booster Clevis 06 06 99

- N0502

- 03 1 na 1 Not required with upgraded HEV
Clevis Pin. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 43.46 $ 17.00

$ 21.17

$ **81.63**

**$** 1.02

$ 8.71

$ 7.29

$ 2.19

$ **19.20**

**$** 0.29

$ **101.12**

**$**

**-**

**$**



### NOTES:



## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  Complete Subsystem Quote (Yes/No) 

## No

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

### Page:4 of 6 

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

DRAFT

0 **n/a n/a** 



# 060600 Brake A **ctuation Subsy stem** 

1 **00 Vehicle Installation of Brake Actuation Subsystem** 

A Vehicle Installation of Brake Actuation Subsystem Components 06 06 00

- N0502

- 01 1 Mod. 1 Additional brake pedal bracket,
fasteners and wire harness connections for Brake-by-wire pedal assembly.Sub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

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

# NEW TECHNOLOGY PACKAGE QUOTE
**PARAMETERS**Assembly 

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

Factor (Default =1) 

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

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



### 2 **01 Master Cylinder and Reservoir** 

A H Master Cylinder 06 06 01

- N0502

- 01 1 na 1 Bore and Stroke Ratios are slightly different between HEV and Base, however it is estimated they would be very similar in cost.



### 3 **02 Pedals** 

A H Brake Pedal Assembly 06 06 02

- N0502

- 01 1 Full 1 Brake-by-wire versus traditional pedal and bracket assembly brake in

base vehicle.



### 4 **03 Brake Lines and Hoses** 

A Brake Line Assembly #1- HCU to Control valve 06 06 03

- N0502

- 01 1 na 1 HEV Part Save - Do not need for HEV as a result of not having Brake
Pressure Control Valve. Costed in Base Brake Actuation System.



### B Brake Line Assembly #2- HCU to Control valve 06 06 03

- N0502

- 02 1 na 1 Same as above



### 5 **05 Brake Control Valves** 

A Brake Pressure Control Valve 06 06 05

- N0502

- 01 1 na 1 HEV able to delete due to regen - braking through front wheels in regen mode.



### 6 **06 Brake Fluid**  **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



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

### Page:5 of 6 

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

DRAFTSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

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

# NEW TECHNOLOGY PACKAGE QUOTE
**PARAMETERS**Assembly 

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

Factor (Default =1) 

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

7 **10 TBD** 

8 **60 Wiring Harness Connections** 

A Wire Harness - Solenoid, Brake Pedal Cut-off Value (3 Pins) 

### 06 06 60

- N0502

- 01 1 Full 1 Required for brake-by-wire



### B Wire Harness - Pressure Sensor, Brake Pedal Cut-off Valve (3 Pins) 

### 06 06 60

- N0502

- 02 1 Full 1 Required for brake-by-wire



### C Wire Harness - Angle Sensor, Brake Pedal & Bracket Assembly (6 Pins) 

### 06 06 60

- N0502

- 03 1 Full 1 Required for brake-by-wire



### D Wire Harness - Brakelamp/Redundant Cruise Deact (4 Pins) 

### 06 06 60

- N0502

- 04 1 na 1 Required for both Base and HEV Configuration.



### 9 **70 Pipes, Hoses, Ducting**  **Investment (X1000)**  **Tooling (x1000)** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 10 **75 Brackets** 

A Bracket - Brake Pedal 06 06 75

- N0502

- 01 1 Full 1



### 11 **80 Boltings** 

A Nut - Pedal & Bracket Assembly Brake to Booster 06 06 80

- N0502

- 01 4 na 1 Required for both Base and HEV Configuration.



### B Bolt - Pedal & Bracket Assembly Brake to Int.Cowl Brkt 06 06 80

- N0502

- 02 2 na 1 Required for both Base and HEV Configuration.



### C Bolt - Cowl Int. Brkt to Cowl Brkt. (Same as B) 06 06 80

- N0502

- 03 2 Full 1 Only required for HEV as a result of additional bracket required to install HEV Brake-by-wire pedal module.

**PIA to Vehicle Installation.**



### D Bolt - Brake Pressure Control Valve 06 06 80

- N0502

- 04 2 na 1 Only required for Base, HEV handles brake loading via regen.

**PIA to Vehicle Installation**

.



### 12 **85 Sealing Elements** 

13 **90 Bearings Elements Misc** 

14 **99 Miscellaneous** 

A Switch - Brake Lamp and Redundant Cruise Deact 06 06 99

- N0502

- 01 1 na 1 Same for Base and HEV
Upgraded Booster Pin for HEV 

### - **$**

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### B Pin - Booster Clevis (Overmolded with anti push-out legs) 06 06 99

- N0502

- 02 1 Full 1 Upgraded Booster Pin for HEV

Estimated Price ≈$1.25


### - **$**

**-**

**$**



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

### Page:6 of 6 

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

DRAFTSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

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

# NEW TECHNOLOGY PACKAGE QUOTE
**PARAMETERS**Assembly 

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

Factor (Default =1) 

# Technology **Level:** Power

- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers 

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

C Clip - Pin, Booster Clevis 06 06 99

- N0502

- 03 1 na 1 Not required with upgraded HEV
Clevis Pin.



### NOTES:



## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  Complete Subsystem Quote (Yes/No) 

## No **Investment (X1000)**  **Tooling (x1000)** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**



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

### Page: 1 of 12 

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

DRAFT


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

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

## Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

## Part Number: **060600-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 1A Vehicle Installation of Brake Actuation

Subsystem Components 060600-N0502-01-01 **1** Load & R/D 

### OEM Vehicle Assembly Not Applicable General Assembly-OEM 

### VO Assembly, OEM, LC **240 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.41**  **$0.06 $0.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.47 $0.47**  **$0.00**

2 2A Vehicle Installation of Brake Actuation

Subsystem Components 060600-N0502-01-02 **1** Connector Insertion 

### OEM Vehicle Assembly Not Applicable General Assembly-OEM 

### VO Assembly, OEM, LC **200 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.49**  **$0.08 $0.56**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.56 $0.56**  **$0.00**

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

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

**0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Differences between HEV and Base Pedal Module Installation:
1. Additional Cowl Bracket Plus two fasteners 2. 3 Additional Wiring connection points, Actuator (Solenoid & Sensor)
and Pedal Position Sensor.

Remaining attachment scheme and hardware same between Base and HEV with exception of clevis pin attachment. One piece design for HEV slightly more complex to assemble than two piece base design,
assume cost neutral.

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

5 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



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

### Page: 2 of 12 

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

DRAFT


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

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

## Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

## Part Number: **060600-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### 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 A H Bolt, Brake Mount Bracket 060680-N0502-03 **2** S **$0.00** $0.10 **$0.00 $0.20**  **$0.20** 

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



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

### Page: 3 of 12 

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

DRAFT


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

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

## Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

## Part Number: **060600-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

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

3 C **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

5 E **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 F **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 G **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

8 H **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 I **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

11 K **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

12 L **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

13 M **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

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

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

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

- up Calculations.

"Alpha

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

13 M **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 N **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

15 O **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**

**Material**

**$0.20**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.23**

**T1 or OEM Total Manufacturing Cost: $0.20**  **$0.89 $0.14**  **$1.23 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.23**

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

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

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

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

**Base Cost Impact to Vehicle: $0.20**  **$0.89 $0.14**  **$1.23 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.23 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.23**  **3 1** 



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



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100"

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447**  

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base



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

### Page: 4 of 12 

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

DRAFT


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

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

## Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

## Part Number: **060600-N0502-01** 

## We ekly Component Volume: Packaging Specification: **n/a**


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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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


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

### Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 5 of 12 

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

DRAFT


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

### Part Description **Part Number**



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

1A Vehicle Installation of Brake Actuation Subsystem Components 060600-N0502-01-01

2A Vehicle Installation of Brake Actuation Subsystem Components 060600-N0502-01-02



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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.41 $0.06**  **$0.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Operator position "Bracket - Brake to Mounting Bracket" to cowl bracket, manual R/D two places. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 43 1 1 15 **1.0 1.0** 

**$0.49 $0.08**  **$0.56 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Route and press in Pedal and Bracket Assembly electrical connections, three places. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 18 **1.0 1.0** 

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

- - - - **1.0 2.0** 

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

- - - - **1.0 1.0**  

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



## Purchase Part - High Impact Item (Full Cost Mapping) Differences between HEV and Base Pedal Module Installation:
1. Additional Cowl Bracket Plus two fasteners 2. 3 Additional Wiring connection points, Actuator (Solenoid & Sensor)
and Pedal Position Sensor.

Remaining attachment scheme and hardware same between Base and HEV with exception of clevis pin attachment. One piece design for HEV slightly more complex to assemble than two piece base design,
assume cost neutral. **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 3.0** 

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

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

- - - - **1.0 2.0** 

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

- - - - **1.1 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



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

### Page: 6 of 12 

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

DRAFT


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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



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

A H Bolt, Brake Mount Bracket 060680-N0502-03 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.20**



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

### Page: 7 of 12 

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

DRAFT


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

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

B

C

D

E

F

G

H

I

J

K

L

M 

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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

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

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00** M

N

O **$0.00**

**$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**

**$0.89 $0.14**  **$1.23 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.23 2** 



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



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

### Page: 8 of 12 

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

DRAFT


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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

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

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

### Page: 9 of 12 

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

DRAFT


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

### Part Description **Part Number**



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

1A Vehicle Installation of Brake Actuation Subsystem Components 060600-N0502-01-01

2A Vehicle Installation of Brake Actuation Subsystem Components 060600-N0502-01-02



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

**240 15.00**  1.00

**200 18.00**  1.00

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

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

-



## Purchase Part - High Impact Item (Full Cost Mapping) Differences between HEV and Base Pedal Module Installation:
1. Additional Cowl Bracket Plus two fasteners 2. 3 Additional Wiring connection points, Actuator (Solenoid & Sensor)
and Pedal Position Sensor.

Remaining attachment scheme and hardware same between Base and HEV with exception of clevis pin attachment. One piece design for HEV slightly more complex to assemble than two piece base design,
assume cost neutral. **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

-

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

-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-

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

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

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

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

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

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

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

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

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

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

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

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

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

-



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

### Page: 10 of 12 

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

DRAFT


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

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

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

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

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

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

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

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

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

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

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

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

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

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

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

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

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

-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-



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

A H Bolt, Brake Mount Bracket 060680-N0502-03 **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

-



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

### Page: 11 of 12 

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

DRAFT


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

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

B

C

D

E

F

G

H

I

J

K

L

M**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

M

N

O



### File:09000064810ec171.xls

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

### Page: 12 of 12 

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

DRAFT


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

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



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

# 0



# 06 **02 H Brake Pedal A**  **ssembly 06**  **06 02** 

**- N0502** 

**- 01** 

H Screw, Brake Pedal Sensor 

# 06 06 02

- N0502

- 02
H Bolt, Brake Mounting Bracket 

# 06 06 02

- N0502

- 03
H Bolt, Brake Mounting Bracket 

# 06 06 02

- N0502

- 04

A **H Bracket, Brake to Mounting Bracket** 

# 06 06 02

- N0502

- 05

H W eld Nut, Bracket, Brake 

# 06 06 02

- N0502

- 06

H W eld Nut, Bracket, Brake 

# 06 06 02

- N0502

- 07

Name/Description Part Number 

# NEW TECHNOLOGY GENERA **L PA RT INFORMA**  **TION:**
**2010 Ford Fusion 2.5L A tkinson Cy**  **cle, I4 156hp (191 Net) Mild HEV (Electric Motor 60kW, Battery**  **275V, Nominal Pack Capacity 5.5A**  **h, 1.51 kWh)** ItemSubsystemSub-SubsystemAssemblySubassemblyComponent 

# Technology **Level: Parallel HEV Technology**  **Vehicle Class: Mid to Large Size Passenger Vehicle, 4** 

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

H Bracket, Brake to Mounting Bracket Shipped in PIA to assembly plant due to required assembly sequence.
06 06 02

- N0502

- 07

B **H Brake Mounting Bracket A sm.**  

# 06 06 02

- N0502

- 08

C **H Brake Pedal Subassembly** 

# 06 06 02

- N0502

- 09

H Screw, Brake Actuator 

# 06 06 02

- N0502

- 10
H Clip, Spring, Brake Pedal Simulator 

# 06 06 02

- N0502

- 11
H Spring, Coil, Brake Pedal Return 

# 06 06 02

- N0502

- 12
H Pivot, Brake Pedal Return Spring 

# 06 06 02

- N0502

- 13
H Latch, Brake Pedal Return Spring 

# 06 06 02

- N0502

- 14

H Pin, Brake, Pivot, Main 

# 06 06 02

- N0502

- 15

H Bracket, Brake Pedal 

# 06 06 02

- N0502

- 16

H Label - Bracket, Brake Pedal 

# 06 06 02

- N0502

- 17

H Pushnut, Fastener 

# 06 06 02

- N0502

- 18
H Screw - Brake Pedal, Stoplight Switch Brkt 

# 06 06 02

- N0502

- 19
H Bracket, Brake Pedal Brakelight Switch 

# 06 06 02

- N0502

- 20

C1 **H Brake Position Sensor & Brkt A sm**  

# 06 06 02

- N0502

- 21

H Brake Position Sensor Asm 

# 06 06 02

- N0502

- 22

H Brake Position Sensor Brkt Insert 

# 06 06 02

- N0502

- 83
H Brake Position Sensor Bearing/race 

# 06 06 02

- N0502

- 84

H Brake Position Sensor Contact 

# 06 06 02

- N0502

- 85
H Brake Position Sensor O-ring 

# 06 06 02

- N0502

- 86

H Circuit system/copper terminals 

# 06 06 02

- N0502

- 87 assembly plant due to required assembly sequence.

# H Brake Position Sensor Bracket Asm 

# 06 06 02

- N0502

- 23

H Brake Position Sensor Housing 

# 06 06 02

- N0502

- 89

H Brake Position Sensor Arm 

# 06 06 02

- N0502

- 90

H Brake Position Sensor Bracket 

# 06 06 02

- N0502

- 24

H Brake Position Sensor Brkt Insert 

# 06 06 02

- N0502

- 25

C2 **H Brake Pedal A ctuator A** 

**sm** 

# 06 06 02

- N0502

- 26
H Housing, Actuator, Brake 

# 06 06 02

- N0502

- 27
H Ball, Plug, Stainless Steel, 3.4 mm 

# 06 06 02

- N0502

- 28
H Coil, Magnetic, Brake Actuator 

# 06 06 02

- N0502

- 29
H Spring, Coil, Piston, Actuator, Br 

# 06 06 02

- N0502

- 30
H Spring, Coil, Actuator, Brake 

# 06 06 02

- N0502

- 31
H Snap Ring - Actuator, Brake 

# 06 06 02

- N0502

- 32

H Nut, Lock, Actuator, Brake 

# 06 06 02

- N0502

- 33

H Clevis, Actuator, Brake 

# 06 06 02

- N0502

- 34
H C-Clip, Brake Actuator Piston 

# 06 06 02

- N0502

- 35

H Label, Brake Pedal Actuator Asm 

# 06 06 02

- N0502

- 36

H Fluid, Actuator, Brake 

# 06 06 02

- N0502

- 37

H W ire, Retaining, Plunger, Brake, Actuator 

# 06 06 02

- N0502

- 38

H Sensor, Pressure, Brake Pedal 

# 06 06 02

- N0502

- 39

C3 **H Piston, A ctuator, Brake**  

# 06 06 02

- N0502

- 40

H Piston, Actuator, W ashed 

# 06 06 02

- N0502

- 41
H O-Ring, Piston, Actuator 

# 06 06 02

- N0502

- 42

C4 **H Cap, Piston Spring A sm**  

# 06 06 02

- N0502

- 43
H Cap, Rim 

# 06 06 02

- N0502

- 44
H Cap, Button 

# 06 06 02

- N0502

- 45

C5 **H Plunger A sm, Brake, A** 

**ctuator** 

# 06 06 02

- N0502

- 46

H Shaft, Actuator, Brake 

# 06 06 02

- N0502

- 47
H Bell Housing, Actuator, Brake 

# 06 06 02

- N0502

- 48 H Bell Housing, Actuator, Brake

H Foam W iper, Actuator, Brake 

# 06 06 02

- N0502

- 49
H Cap, Plunger, Actuator 

# 06 06 02

- N0502

- 50

C5A **H Stud and O-Ring A sm, A**  **ctuator** 

# 06 06 02

- N0502

- 51

H Stud, Threaded, Actuator, Brake 

# 06 06 02

- N0502

- 52
H O-Ring, Stud, Actuator, Brake 

# 06 06 02

- N0502

- 53
H Retainer, Plunger, Actuator, Brake 

# 06 06 02

- N0502

- 54

C6 **H Brake Pedal and Simulator A sm**  

# 06 06 02

- N0502

- 55

C6A **H Brake Pedal A rm Subassembly**  

# 06 06 02

- N0502

- 56
H Bumper, Brake Pedal 

# 06 06 02

- N0502

- 57
H Bushing, Brake Pedal Pivot 

# 06 06 02

- N0502

- 58

H Contact Cover, Brake Pedal 

# 06 06 02

- N0502

- 59

C6A1 **H Brake Pedal A rm, Weldment, Painted**  

# 06 06 02

- N0502

- 60

H Brake Pedal Arm, Partial W eldment 

# 06 06 02

- N0502

- 61
H Pin, Brake Pedal Spring Pivot 

# 06 06 02

- N0502

- 62

H Tube, Pivot, Brake Pedal Arm 

# 06 06 02

- N0502

- 63
H Bar, Brake Pedal Spring 

# 06 06 02

- N0502

- 64
H Bracket, Brake Pedal Stop 

# 06 06 02

- N0502

- 65

H Pedal Contact, Brake Pedal 

# 06 06 02

- N0502

- 66

C6B **H Simulator, Brake Pedal A sm**  

# 06 06 02

- N0502

- 67
H Bumper, Leaf Spring, Simulator 

# 06 06 02

- N0502

- 68

# H Cover, Simulator, Brake Pedal 

# 06 06 02

- N0502

- 69
H O-Ring, NVH, Simulator Shaft 

# 06 06 02

- N0502

- 70
H Screw, Cover, Brake Pedal Spring, Primary 

# 06 06 02

- N0502

- 71

C6B1 **H Spring, Leaf, Simulator A sm**  

# 06 06 02

- N0502

- 72
H Spring, Leaf, Simulator 

# 06 06 02

- N0502

- 73
H Pad, Spring, Leaf 

# 06 06 02

- N0502

- 74
H Pad #2, Leaf Spring 

# 06 06 02

- N0502

- 75

C6B2 **H Spring, Rubber Bumper, Plate A sm.**  

# 06 06 02

- N0502

- 88
H Spring, Rubber Bumper 

# 06 06 02

- N0502

- 76
H Plate, Spring, Rubber Bumper 

# 06 06 02

- N0502

- 77

C6B3 **H Housing A**

**sm., Simulator, Brake Pedal** 

# 06 06 02

- N0502

- 78
H Housing , Simulator, Brake Pedal 

# 06 06 02

- N0502

- 79

H Pin, Simulator - Actuator 

# 06 06 02

- N0502

- 80
H Pin, Dowel, Split, Simulator Housing 

# 06 06 02

- N0502

- 81
H Bushing, Brake Simulator Housing 

# 06 06 02

- N0502

- 82

**NOTES:**



# 1. **= A**

**highlighted Sub-subsystem, A ssembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**  **the competing technology**

# Material Labor Burden

**- $** 

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**1**

- $

-

$

-

$

2 PIA

2 PIA

2 PIA

1



# - $

-

$

-

$

1 PIA

1 PIA 

# ManufacturingQTY/Subsystem 

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

Factor (Default =1) Notes 

# NEW TECHNOLOGY PA **CKA GE QUOTE** 

**PA RA**  **METERS 6 Passengers**  **N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class** 

1 PIA

1 Not Mapped - Beyond Scope

1 

# 3.23 $ 3.02

$ 3.85

$

2 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 

# 3.93 $ 0.89

$ 0.39

$

1 PIA

2 PIA

1 PIA

1 PIA

1 PIA

1 PIA

# 1 PIA

1 PIA

1 PIA

1 PIA

2 PIA

1 

# 19.70 $ 4.15

$ 3.04

$

1 PIA

5 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

2 

# 0.46 $ 0.46

$ 0.76

$

2 PIA

2 PIA

1 

# 0.04 $ 0.06

$ 0.04

$

1 PIA

1 PIA

1 

# 2.25 $ 0.32

$ 0.77

$

1 PIA

1 PIA

1 PIA

1 PIA

1 

# 1.00 $ 0.39

$ 0.69

$

1 PIA

1 PIA

1 PIA

1



# - $ 0.04

$ 0.06

$

1 

# 0.62 $ 0.20

$ 0.97

$

1 PIA

1 PIA

1 PIA

1 

# 6.12 $ 1.20

$ 3.94

$

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 PIA

1 

# 0.31 $ 0.71

$ 0.77

$

1 PIA

# 1 PIA

3 PIA

2 PIA

1 

# 0.18 $ 0.26

$ 0.62

$

1 PIA

1 PIA

1 PIA

1



# - $

-

$

-

$

1 PIA 

# 0.12 $ 0.67

$ 0.69

$

1 PIA

1 

# 1.46 $ 1.64

$ 2.66

$

1 PIA

1 PIA

2 PIA

2 PIA



# 39.43 $ 14.02

$ 19.25

$ Complete Subsy stem Quote

(Yes/No)

**= A**

**highlighted Sub-subsystem, A ssembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of** 

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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - **$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$** #REF!

**- $** 



# - **$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$ Total**  **Packaging**

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

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

**OEM Total**  **Manufacturing**

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

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

# NEW TECHNOLOGY PA **CKA GE COST INFORMA**  **TION**

**10.10 $**  0.27

$ 1.33

$ 1.07

$ 0.28

$ **2.96**

**$** 0.22

$ **13.29**

**$**



# 5.21 **$** 0.03

$ 0.44

$ 0.38

$ 0.13

$ **0.99**

**$**

-

$ **6.20**

**$**

# 26.89

**$** 0.32

$ 2.47

$ 2.12

$ 0.70

$ **5.61**

**$**

-

$ **32.50**

**$**



# 1.68 **$** 0.01

$ 0.21

$ 0.17

$ 0.05

$ **0.44**

**$**

-

$ **2.12**

**$**



# 0.14 **$** 0.00

$ 0.02

$ 0.01

$ 0.00

$ **0.04**

**$**

-

$ **0.18**

**$**

**3.33 $**  0.03

$ 0.44

$ 0.35

$ 0.09

$ **0.91**

**$**

-

$ **4.24**

**$**

**2.08 $**  0.02

$ 0.27

$ 0.22

$ 0.06

$ **0.56**

**$**

-

$ **2.64**

**$**



# 0.10 **$** 0.00

$ 0.01

$ 0.01

$ 0.00

$ **0.03**

**$**

-

$ 0.13

$



# 1.80 **$** 0.01

$ 0.21

$ 0.17

$ 0.05

$ **0.45**

**$**

-

$ **2.25**

**$**



# 11.27 **$** 0.11

$ 1.51

$ 1.31

$ 0.37

$ **3.29**

**$**

-

$ **14.56**

**$**



# 1.79 **$** 0.01

$ 0.23

$ 0.18

$ 0.05

$ **0.48**

**$**

-

$ **2.27**

**$**

# 1.06

**$** 0.01

$ 0.14

$ 0.11

$ 0.03

$ **0.29**

**$**

-

$ **1.35**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$** 1.89

$

**-**

**$**



# 1.48 **$** 0.01

$ 0.19

$ 0.16

$ 0.04

$ **0.41**

**$**

-

$ **1.89**

**$**



# 5.77 **$** 0.14

$ 0.74

$ 0.60

$ 0.16

$ **1.64**

**$**

-

$ **7.40**

**$**

**72.71 $**  0.98

$ 8.22

$ 6.87

$ 2.02

$ **18.09**

**$** 0.22

$ **91.02**

**$**

# -

**$**

**-**

**$**

**-**

**$**

**- $**  **Investment (X1000)**  **Sy stem** 
**ED&T/R&D (x1000)**  **Tooling**

**(x1000)**

# -

**$**

**-**

**$**

**-**

**$**

### Page: 1 of 6 

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

DRAFT


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

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

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

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

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

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

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 H Bracket, Brake to Mounting Bracket 060602-N0502-05 **1** Weldment 

### T1 Assembly, Mark-up Applied @ Bottom. MC-Steel-1000S, Coil Welding/Soldering Operator Mech. Assembly, LC **189 0.25**  **1 1**  0.000 **$0.55 $41.55**  **$100.00 $100.00**  **$0.00 $0.05**  **$0.53 $0.58**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.58 $0.58**  **$0.00**

3 060602-N0502-05A **1** Vertical Stamping Press, Tonnage 200-400 

### T1 Assembly, Mark-up

Applied @ Bottom. MC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **2000 0.5**  **1 1**  1.243 **$0.55 $42.73**  **$42.91 $42.91**  **$0.68 $0.01**  **$0.02 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.68**

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**



### 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**



### 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 H W eld Nut, Bracket, Brake 060602-N0502-06 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

3 H W eld Nut, Bracket, Brake 060602-N0502-07 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05**

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

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.78**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.40** 

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

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

**1**

**T1 or OEM Total Manufacturing Cost: $0.78**  **$0.07 $0.55**  **$1.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.40**

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

----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

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

----- ----- ----- **$0.00 $0.08**  **$0.06 $0.01**  **$0.16**

**Base Cost Impact to Vehicle: $0.78**  **$0.07 $0.55**  **$1.40 $0.00**  **$0.08 $0.06**  **$0.01 $0.16**  **$1.56 $0**  **$0**

**Packaging Cost: $0.01** 

**Net Cost Impact to Vehicle: $1.56**  **3** 

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



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



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

### Page: 2 of 6 

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

DRAFT


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

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

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

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

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

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

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

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

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


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

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 3 of 6 

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

DRAFT


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

### Part Description **Part Number**



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

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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  

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

H Bracket, Brake to Mounting Bracket 060602-N0502-05

060602-N0502-05A



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

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

H W eld Nut, Bracket, Brake 060602-N0502-06

H W eld Nut, Bracket, Brake 060602-N0502-07 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.05 $0.53**  **$0.58 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Spot projection weld auto load **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19 2 1 19 **1.0 1.0** 

**$0.01 $0.02**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Progressive, 300 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 1 1.8 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.05**

**$0.05**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.07 $0.55**  **$1.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.40 2** 



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



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

### Page: 4 of 6 

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

DRAFT


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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

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

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

### Page: 5 of 6 

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

DRAFT


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

### Part Description **Part Number**



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

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

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

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

-

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

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

-

H Bracket, Brake to Mounting Bracket 060602-N0502-05

060602-N0502-05A



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

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

H W eld Nut, Bracket, Brake 060602-N0502-06

H W eld Nut, Bracket, Brake 060602-N0502-07 **#DIV/0! #DIV/0!** 

-

**189 19.00**  0.25

**2000 1.80**  0.50

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

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

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

-

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

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

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

-



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

### Page: 6 of 6 

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

DRAFT


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

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



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

### Page: 1 of 6 

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

DRAFT


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

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

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

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

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

1 H Brake Pedal Subassembly 060602-N0502-09 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **133 5**  **5 1**  0.000 **$0.00 $38.55**  **$15.00 $75.00**  **$0.00 $1.45**  **$0.56 $2.01**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.21**  **$2.21 $2.21**  **$0.00**

1
H Latch, Brake Pedal Return Spring 060602-N0502-14 **1** H Latch, Brake Pedal Return Spring, Mold T2/T3 Inject. Mold, SSLC PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **1393 0.5**  **1 1**  0.031 **$1.46 $41.48**  **$16.39 $16.39**  **$0.05 $0.01**  **$0.01 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.05**

2
H Pivot, Brake Pedal Return Spring 060602-N0502-13 **1** H Pivot, Brake Pedal Return Spring, Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **126 0.5**  **1 1**  0.028 **$1.54 $41.48**  **$16.39 $16.39**  **$0.04 $0.16**  **$0.13 $0.34**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.37 $0.37**  **$0.04**

3 H Bracket, Brake Pedal Brakelight Switch 060602-N0502-20 **1** Vertical Stamping Press, Tonnage 200-400 T2/T3 Stamp/Form, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **2118 0.5**  **1 1**  0.120 **$0.55 $42.73**  **$42.91 $42.91**  **$0.07 $0.01**  **$0.02 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.07**

4 H Pin, Brake, Pivot, Main 060602-N0502-15 **1** 1 Wash Cycles thru machining T2/T3 Mech. Assembly, SSLC MC-Steel-1018, Bar CNC Operator Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.74 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

H Pin, Brake, Pivot, Main 060602-N0502-15A **1** Electroplate T2/T3 Plate/Finish Mech.,

SSLC MC-Steel-1018, Bar Plating/Coating Operator Plate/Finish, SMS, MHC **184 0.25**  **0.5 1**  0.000 **$0.74 $40.84**  **$125.00 $62.50**  **$0.00 $0.06**  **$0.34 $0.40**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.44 $0.44**  **$0.00**

5 H Pin, Brake, Pivot, Main 060602-N0502-15B **1** Machine T2/T3 CNC Milling, SSLC MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA **189 1**  **1 1**  0.420 **$0.74 $36.98**  **$20.48 $20.48**  **$0.31 $0.20**  **$0.11 $0.61**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.68 $0.68**  **$0.31**

3 H Bracket, Brake Pedal 060602-N0502-16 **1** 1 Wash Cycles thru machining T2/T3 Mech. Assembly, SSLC Aluminum-332, Cast CNC Operator Washing Equipment, MC **300 0.25**  **1 1**  0.000 **$1.24 $36.98**  **$49.38 $49.38**  **$0.00 $0.03**  **$0.16 $0.20**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.22 $0.22**  **$0.00**

4 H Bracket, Brake Pedal 060602-N0502-16A **1** Machine T2/T3 CNC Milling, SSLC Aluminum-332, Cast CNC Operator CNC Machining, MC **119 2**  **3 1**  0.000 **$1.24 $36.98**  **$45.37 $136.11**  **$0.00 $0.62**  **$1.15 $1.77**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.18**  **$1.95 $1.95**  **$0.00**

5 H Bracket, Brake Pedal 060602-N0502-16B **1** Heat Treat T2/T3 Heat Treat, SSLC Aluminum-332, Cast Heat Treat Operator T5-Al380, SMS **285 1.5**  **1 1**  2.032 **$0.01 $47.72**  **$10.17 $10.17**  **$0.02 $0.25**  **$0.04 $0.31**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.34 $0.34**  **$0.02**

10 H Bracket, Brake Pedal 060602-N0502-16C **1** Housing-Cast T2/T3 Diecast, SSLC Aluminum-332, Cast Mold/Cast/Sinter Operator Diecast, MLS **211 1**  **1 1.1**  2.032 **$1.24 $41.48**  **$247.89 $272.68**  **$2.52 $0.20**  **$1.30 $4.01**  **5.00% 6.00%**  **4.00% 0.00%**  **15.00% $0.60**  **$4.61 $4.61**  **$2.52**

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**



### 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**



### 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 H Screw, Brake Actuator 060602-N0502-10 **1** S **$0.00** $0.075 **$0.00 $0.08**  **$0.08**

3 H Clip, Spring, Brake Pedal Simulator 060602-N0502-11 **1** S **$0.00** $0.005 **$0.00 $0.01**  **$0.01**

4 H Spring, Coil, Brake Pedal Return 060602-N0502-12 **1** S **$0.00** $0.07 **$0.00 $0.07**  **$0.07**

5 H Pushnut, Fastener 060602-N0502-18 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

6 H Screw - Brake Pedal, Stoplight Switch Brkt 060602-N0502-19 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

7 H Label - Bracket, Brake Pedal 060602-N0502-17 **1** S **$0.00** $0.05 **$0.00 $0.05**  **$0.05** 

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

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

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

- up Calculations.



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

### Page: 2 of 6 

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

DRAFT


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

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

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

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

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$3.23**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$11.31**

**T1 or OEM Total Manufacturing Cost: $3.23**  **$3.02 $3.85**  **$10.10 $0.22**  **$0.59 $0.40**  **$0.00 $1.21**  **$11.31**

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

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

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

----- ----- ----- **$0.06 $0.74**  **$0.68 $0.28**  **$1.75** 

### "Alpha

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

**3 1** 



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

**Base Cost Impact to Vehicle: $3.23**  **$3.02 $3.85**  **$10.10 $0.27**  **$1.33 $1.07**  **$0.28 $2.96**  **$13.06 $0**  **$0**

**Packaging Cost: $0.22** 

**Net Cost Impact to Vehicle: $13.29** 

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.223 $446,880**  **0.00% 2,250,000**  **60 5.00%**  $280 **1596** 36 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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


### Packaging Cost Total: **$0.223** 

### PACKAGING CALCULATIONS: Packaging Type: Optioin #1

- Cell Packed Part Size: 400x200X300 Parts/Layer: 3x3 Number of Layers:4 **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 3 of 6 

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

DRAFT


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

### Part Description **Part Number**



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

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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  

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

H Brake Pedal Subassembly 060602-N0502-09

H Latch, Brake Pedal Return Spring 060602-N0502-14

H Pivot, Brake Pedal Return Spring 060602-N0502-13

H Bracket, Brake Pedal Brakelight Switch 060602-N0502-20

H Pin, Brake, Pivot, Main 060602-N0502-15

H Pin, Brake, Pivot, Main 060602-N0502-15A

H Pin, Brake, Pivot, Main 060602-N0502-15B

H Bracket, Brake Pedal 060602-N0502-16

H Bracket, Brake Pedal 060602-N0502-16A

H Bracket, Brake Pedal 060602-N0502-16B

H Bracket, Brake Pedal 060602-N0502-16C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$1.45 $0.56**  **$2.01 $0.01**  **$0.12 $0.08**  **$0.00 $0.21**  5 operator, 5 station. Attach brake pedal position sensor/bracket asm and attach brake pedal actuator asm to brake pedal bracket with two screws each.. Attach Latch, Pivot to spring, compress and lock in place.Take pin, brake pivot and brake pedal bracket brake pedal simulator assembly and press together.screw brake pedal backlight bracket to brake pedal simulator assembly. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 135 7 1 135 **1.00 5.0** 

**$0.01 $0.01**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  9 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2.6 1 9 23.3 **1.0 1.0** 

**$0.16 $0.13**  **$0.34 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  9 Cavity Mold, High cycle time due to solid shaft **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 28.5 1 9 256.5 **1.0 1.0** 

**$0.01 $0.02**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  200 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.7 1 1 1.7 **1.0 1.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  Washer Duo 400 Wash Rinse & Dry **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.06 $0.34**  **$0.40 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  Zinc Plating, Batched Processed **1 1**  **10 10**  **47 470**  **957 3.76**  **85% 1126**  **3.20** 9.8 1 1 9.8 **1.0 0.5** 

**$0.20 $0.11**  **$0.61 $0.00**  **$0.04 $0.02**  **$0.00 $0.06**  SL-10 auto feed **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19 7 1 19 **1.0 1.0** 

**$0.03 $0.16**  **$0.20 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Washer Duo 400 Wash Rinse & Dry **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12 5 1 12 **1.0 1.0** 

**$0.62 $1.15**  **$1.77 $0.01**  **$0.11 $0.07**  **$0.00 $0.18**  EC-300-ML Horizontal CNC **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 91 18 1 91 **1.0 3.0** 

**$0.25 $0.04**  **$0.31 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  T5 Heat Treat **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 2,140 27,000 **1.0 1.0** 

**$0.20 $1.30**  **$4.01 $0.20**  **$0.24 $0.16**  **$0.00 $0.60**  1.1 Multiplier used for trimming, + 2 seconds - cast with pin **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 17.10 2 4 68.4 **1.1 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



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

H Screw, Brake Actuator 060602-N0502-10
H Clip, Spring, Brake Pedal Simulator 060602-N0502-11
H Spring, Coil, Brake Pedal Return 060602-N0502-12

H Pushnut, Fastener 060602-N0502-18
H Screw - Brake Pedal, Stoplight Switch Brkt 060602-N0502-19

H Label - Bracket, Brake Pedal 060602-N0502-17 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.08**

**$0.01**

**$0.07**

**$0.01**

**$0.01**

**$0.05**



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

### Page: 4 of 6 

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

DRAFT


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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

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

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$3.02 $3.85**  **$10.10 $0.22**  **$0.59 $0.40**  **$0.00 $1.21** 

**$11.31 2** 



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



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

### Page: 5 of 6 

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

DRAFT


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

### Part Description **Part Number**



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

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

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

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

-

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

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

-

H Brake Pedal Subassembly 060602-N0502-09

H Latch, Brake Pedal Return Spring 060602-N0502-14

H Pivot, Brake Pedal Return Spring 060602-N0502-13

H Bracket, Brake Pedal Brakelight Switch 060602-N0502-20

H Pin, Brake, Pivot, Main 060602-N0502-15

H Pin, Brake, Pivot, Main 060602-N0502-15A

H Pin, Brake, Pivot, Main 060602-N0502-15B

H Bracket, Brake Pedal 060602-N0502-16

H Bracket, Brake Pedal 060602-N0502-16A

H Bracket, Brake Pedal 060602-N0502-16B

H Bracket, Brake Pedal 060602-N0502-16C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **133 27.00**  5.00

**1393 2.59**  0.50

**126 28.50**  0.50

**2118 1.70**  0.50

**277 13.00**  0.25

**184 19.60**  0.25

**189 19.00**  1.00

**300 12.00**  0.25

**119 30.33**  2.00

**285 12.62**  1.50

**211 17.10**  1.00

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

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

-

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

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

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

-



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

H Screw, Brake Actuator 060602-N0502-10
H Clip, Spring, Brake Pedal Simulator 060602-N0502-11
H Spring, Coil, Brake Pedal Return 060602-N0502-12

H Pushnut, Fastener 060602-N0502-18
H Screw - Brake Pedal, Stoplight Switch Brkt 060602-N0502-19

H Label - Bracket, Brake Pedal 060602-N0502-17 **#DIV/0! #DIV/0!** 

-



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

### Page: 6 of 6 

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

DRAFT


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

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



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

### Page: 1 of 6 

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

DRAFT


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

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

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

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

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

1 H Brake Position Sensor & Brkt. Asm 060602-N0502-21 **1** Assembly T2/T3 Mech. Assembly, SSLC Nylon66-30GF, Inject. General Assembly Mech Assembly, LC, Base **300 1**  **1 1**  0.000 **$1.54 $38.55**  **$15.00 $15.00**  **$0.00 $0.13**  **$0.05 $0.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.20 $0.20**  **$0.00**

2 H Brake Position Sensor Asm 060602-N0502-22 **1** Assembly T2/T3 Mech. Assembly, SSLC Nylon66-30GF, Inject. General Assembly Mech Assembly, LC, Base **120 2**  **2 1**  0.000 **$1.54 $38.55**  **$15.00 $30.00**  **$0.00 $0.64**  **$0.25 $0.89**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.09**  **$0.98 $0.98**  **$0.00**

3 H Brake Position Sensor Housing 060602-N0502-89 **1** H Brake Position Sensor Housing, mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **2000 0.5**  **1 1**  0.100 **$1.54 $41.48**  **$16.39 $16.39**  **$0.15 $0.01**  **$0.01 $0.17**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.19 $0.19**  **$0.15**

4 H Brake Position Sensor Arm 060602-N0502-90 **1** H Brake Position Sensor Arm,

mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **2000 0.5**  **1 1**  0.050 **$1.54 $41.48**  **$16.39 $16.39**  **$0.08 $0.01**  **$0.01 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.08**

5 H Brake Position Sensor Bracket Asm 060602-N0502-23 **1** Assembly T2/T3 Mech. Assembly, SSLC Nylon66-30GF, Inject. General Assembly Mech Assembly, LC, Base **225 0.5**  **1 1**  0.000 **$1.54 $38.55**  **$15.00 $15.00**  **$0.00 $0.09**  **$0.07 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.17 $0.17**  **$0.00**

6 H Brake Position Sensor Bracket 060602-N0502-24 **1** H Brake Position Sensor Bracket, mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **2000 0.5**  **1 1**  0.033 **$1.54 $41.48**  **$16.39 $16.39**  **$0.05 $0.01**  **$0.01 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.05**

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**



### 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**



### 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 H Brake Position Sensor Brkt Insert 060602-N0502-25 **2** S **$0.00** $0.03 **$0.00 $0.06**  **$0.06**

3 H Brake Position Sensor Bearing/race 060602-N0502-84 **1** S **$0.00** $2.00 **$0.00 $2.00**  **$2.00**

4 H Brake Position Sensor Contact 060602-N0502-85 **1** S **$0.00** $1.00 **$0.00 $1.00**  **$1.00**

5 H Brake Position Sensor O-ring 060602-N0502-86 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

6 H Circuit system/copper terminals 060602-N0502-87 **1** Insert circuit system/copper

terminals and over mold S **$0.00** $0.50 **$0.00 $0.50**  **$0.50** 

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

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

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

- up Calculations. terminals and over mold

7 H Brake Position Sensor Asm Insert 060602-N0502-83 **2** S **$0.00** $0.03 **$0.00 $0.06**  **$0.06**

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$3.93**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$5.37**

**T1 or OEM Total Manufacturing Cost: $3.93**  **$0.89 $0.39**  **$5.21 $0.00**  **$0.09 $0.06**  **$0.00 $0.16**  **$5.37** 

### "Alpha

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

**3 1** 



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



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

### Page: 2 of 6 

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

DRAFT


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

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

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

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

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

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

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

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

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

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

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

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

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

----- ----- ----- **$0.03 $0.35**  **$0.32 $0.13**  **$0.83**

**Base Cost Impact to Vehicle: $3.93**  **$0.89 $0.39**  **$5.21 $0.03**  **$0.44 $0.38**  **$0.13 $0.99**  **$6.20 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $6.20** **C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) **Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

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

**Pieces Number of** 

**Months Interest** 

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



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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


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

### Part Size: Parts/Layer: Number of Layers: Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



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

### Page: 3 of 6 

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

DRAFT


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

### Part Description **Part Number**



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

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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  

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

H Brake Position Sensor & Brkt. Asm 060602-N0502-21

H Brake Position Sensor Asm 060602-N0502-22

H Brake Position Sensor Housing 060602-N0502-89

H Brake Position Sensor Arm 060602-N0502-90

H Brake Position Sensor Bracket Asm 060602-N0502-23

H Brake Position Sensor Bracket 060602-N0502-24



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

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

H Brake Position Sensor Brkt Insert 060602-N0502-25
H Brake Position Sensor Bearing/race 060602-N0502-84

H Brake Position Sensor Contact 060602-N0502-85
H Brake Position Sensor O-ring 060602-N0502-86

H Circuit system/copper terminals 060602-N0502-87 **$0.13 $0.05**  **$0.18 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Press plastic mounting adapters inserts on bracket into sensor asm. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12 1 1 12 **1.00 1.0** 

**$0.64 $0.25**  **$0.89 $0.00**  **$0.05 $0.04**  **$0.00 $0.09**  Press inserts onto bracket, apply O-ring, Press lever onto contact, pot with epoxy and then laser etch. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 60 6 1 60 **1.00 2.0** 

**$0.01 $0.01**  **$0.17 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  6 Cavity Mold, Overmold terminals, bearing/race and contact **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 6 10.8 **1.0 1.0** 

**$0.01 $0.01**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2 1 6 11 **1.0 1.0** 

**$0.09 $0.07**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Press inserts onto bracket **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 16 2 1 16 **1.00 1.0** 

**$0.01 $0.01**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  6 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 6 10.8 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.06**

**$2.00**

**$1.00**

**$0.03**

**$0.50**

H Brake Position Sensor Asm Insert 060602-N0502-83 **$0.06**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.89 $0.39**  **$5.21 $0.00**  **$0.09 $0.06**  **$0.00 $0.16** 

**$5.37 2** 



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



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

### Page: 4 of 6 

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

DRAFT


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

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



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

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

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

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

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

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



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

### Page: 5 of 6 

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

DRAFT


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

### Part Description **Part Number**



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

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

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

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

-

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

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

-

H Brake Position Sensor & Brkt. Asm 060602-N0502-21

H Brake Position Sensor Asm 060602-N0502-22

H Brake Position Sensor Housing 060602-N0502-89

H Brake Position Sensor Arm 060602-N0502-90

H Brake Position Sensor Bracket Asm 060602-N0502-23

H Brake Position Sensor Bracket 060602-N0502-24



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

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

H Brake Position Sensor Brkt Insert 060602-N0502-25
H Brake Position Sensor Bearing/race 060602-N0502-84

H Brake Position Sensor Contact 060602-N0502-85
H Brake Position Sensor O-ring 060602-N0502-86

H Circuit system/copper terminals 060602-N0502-87 **300 12.00**  1.00

**120 30.00**  2.00

**2000 1.80**  0.50

**2000 1.80**  0.50

**225 16.00**  0.50

**2000 1.80**  0.50

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

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

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

-

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

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

-

H Brake Position Sensor Asm Insert 060602-N0502-83



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

### Page: 6 of 6 

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

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Brake Pedal Actuator Asm 060602-N0502-26 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **116 9**  **9 1**  0.000 **$0.00 $38.55**  **$15.00 $135.00**  **$0.00 $2.99**  **$1.16 $4.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.43**  **$4.58 $4.58**  **$0.00**

2 H Clevis, Actuator, Brake 060602-N0502-34 **1** 1 Wash Cycles thru machining T2/T3 Mech. Assembly, SSLC S-Steel-304, Bar CNC Operator Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$1.65 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

3 H Clevis, Actuator, Brake 060602-N0502-34A **1** Machine T2/T3 CNC Milling, SSLC S-Steel-304, Bar CNC Operator CNC Turning, SS, BF, DA **138 1**  **1 1**  0.000 **$1.65 $36.98**  **$20.48 $20.48**  **$0.00 $0.27**  **$0.15 $0.42**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.46 $0.46**  **$0.00**

4 H Clevis, Actuator, Brake 060602-N0502-34B **1** Machine T2/T3 CNC Milling, SSLC S-Steel-304, Bar CNC Operator CNC Turning, SS, BF, DA **164 1**  **1 1**  0.240 **$1.65 $36.98**  **$20.48 $20.48**  **$0.40 $0.23**  **$0.13 $0.75**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.08**  **$0.82 $0.82**  **$0.40**

5 H Housing, Actuator, Brake 060602-N0502-27 **1** 1 Wash Cycles thru machining T2/T3 Mech. Assembly, SSLC Aluminum-7075-T6, Ext. CNC Operator Washing Equipment, MC **277 0.25**  **1 1**  0.000 **$3.21 $36.98**  **$49.38 $49.38**  **$0.00 $0.03**  **$0.18 $0.21**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.23 $0.23**  **$0.00**

6 H Housing, Actuator, Brake 060602-N0502-27A **1** Machine T2/T3 CNC Milling, SSLC Aluminum-7075-T6, Ext. CNC Operator CNC Machining, LMC **128 2**  **5 1**  0.000 **$3.21 $36.98**  **$34.48 $172.40**  **$0.00 $0.58**  **$1.35 $1.93**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.20**  **$2.13 $2.13**  **$0.00**

7 H Housing, Actuator, Brake 060602-N0502-27B **1** Cut T2/T3 Diecast, SSLC Aluminum-7075-T6, Ext. Mold/Cast/Sinter Operator Mech Assembly, MC, Base **900 0.5**  **1 1**  0.970 **$3.21 $41.48**  **$30.00 $30.00**  **$3.11 $0.02**  **$0.03 $3.17**  **5.00% 6.00%**  **4.00% 0.00%**  **15.00% $0.48**  **$3.65 $3.65**  **$3.11**

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**



### 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**



### 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 H Spring, Coil, Piston, Actuator, Br 060602-N0502-30 **1** S **$0.00** $0.070 **$0.00 $0.07**  **$0.07**

3 H Spring, Coil, Actuator, Brake 060602-N0502-31 **1** S **$0.00** $0.950 **$0.00 $0.95**  **$0.95**

4 H Snap Ring - Actuator, Brake 060602-N0502-32 **1** S **$0.00** $0.04 **$0.00 $0.04**  **$0.04**

5 H Nut, Lock, Actuator, Brake 060602-N0502-33 **1** S **$0.00** $0.15 **$0.00 $0.15**  **$0.15**

H C-Clip, Brake Actuator Piston 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for 6 H C-Clip, Brake Actuator Piston 060602-N0502-35 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

7 H Label, Brake Pedal Actuator Asm 060602-N0502-36 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

8 H Sensor, Pressure, Brake Pedal 060602-N0502-39 **1** S **$0.00** $10.00 **$0.00 $10.00**  **$10.00**

9 H Wire, Retaining, Plunger, Brake, Actuator 060602-N0502-38 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

10 H Ball, Plug, Stainless Steel, 3.4 mm 060602-N0502-28 **5** S **$0.00** $0.02 **$0.00 $0.10**  **$0.10**

11 H Coil, Magnetic, Brake Actuator 060602-N0502-29 **1** S **$0.00** $4.65 **$0.00 $4.65**  **$4.65**

12 H Fluid, Actuator, Brake 060602-N0502-37 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material** 

### 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.



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**$19.70**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$28.14**

**T1 or OEM Total Manufacturing Cost: $19.70**  **$4.15 $3.04**  **$26.89 $0.18**  **$0.64 $0.43**  **$0.00 $1.25**  **$28.14**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.14 $1.83**  **$1.69 $0.70**  **$4.36**

**Base Cost Impact to Vehicle: $19.70**  **$4.15 $3.04**  **$26.89 $0.32**  **$2.47 $2.12**  **$0.70 $5.61**  **$32.50 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $32.50**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

H Brake Pedal Actuator Asm 060602-N0502-26

H Clevis, Actuator, Brake 060602-N0502-34

H Clevis, Actuator, Brake 060602-N0502-34A

H Clevis, Actuator, Brake 060602-N0502-34B

H Housing, Actuator, Brake 060602-N0502-27

H Housing, Actuator, Brake 060602-N0502-27A

H Housing, Actuator, Brake 060602-N0502-27B



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Spring, Coil, Piston, Actuator, Br 060602-N0502-30
H Spring, Coil, Actuator, Brake 060602-N0502-31
H Snap Ring - Actuator, Brake 060602-N0502-32

H Nut, Lock, Actuator, Brake 060602-N0502-33
H C-Clip, Brake Actuator Piston **$2.99 $1.16**  **$4.15 $0.01**  **$0.25 $0.17**  **$0.00 $0.43**  9 station, 9 operator. Press and swage 5 Stainless steel balls into actuator housing.Assemble acutator coil to housing. Insert piston & spring, compress and apply cap & button - retain w/c-clip. Place fuild in housing and bleed.Insert 2nd piston in opposite end w/ plunger assembly and apply retainer and retaining wire - seal in place with sealant. Insert and compress spring - hold in place with retainer and lock nut. Attach clevis to plunger asm. Attach pressure sensor. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 279 19 1 279 **1.00 9.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 

Washer Duo 400 Wash Rinse & Dry **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.27 $0.15**  **$0.42 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  SL-10 auto feed Drill, chamfer, drill/tap,debur/tumble **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 26 4 1 26 **1.0 1.0** 

**$0.23 $0.13**  **$0.75 $0.00**  **$0.04 $0.03**  **$0.00 $0.08**  SL-10 auto feed shape od & chamfer **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 22 6 1 22 **1.0 1.0** 

**$0.03 $0.18**  **$0.21 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  In line Washer Specialzed spray nozzles **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.58 $1.35**  **$1.93 $0.01**  **$0.12 $0.08**  **$0.00 $0.20**  5 station, 5 operator EC-400-ML Horizontal CNC Machine (bore, drill, mill, groove, engrave and camfer) block **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 141 33 1 141 **1.0 5.0** 

**$0.02 $0.03**  **$3.17 $0.16**  **$0.19 $0.13**  **$0.00 $0.48**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.07**

**$0.95**

**$0.04**

**$0.15**
H C-Clip, Brake Actuator Piston 060602-N0502-35

H Label, Brake Pedal Actuator Asm 060602-N0502-36
H Sensor, Pressure, Brake Pedal 060602-N0502-39
H Wire, Retaining, Plunger, Brake, Actuator 060602-N0502-38
H Ball, Plug, Stainless Steel, 3.4 mm 060602-N0502-28
H Coil, Magnetic, Brake Actuator 060602-N0502-29

H Fluid, Actuator, Brake 060602-N0502-37 **$0.02**

**$0.10**

**$10.00**

**$0.01**

**$0.10**

**$4.65**

**$0.10**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$4.15 $3.04**  **$26.89 $0.18**  **$0.64 $0.43**  **$0.00 $1.25** 

**$28.14 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Brake Pedal Actuator Asm 060602-N0502-26

H Clevis, Actuator, Brake 060602-N0502-34

H Clevis, Actuator, Brake 060602-N0502-34A

H Clevis, Actuator, Brake 060602-N0502-34B

H Housing, Actuator, Brake 060602-N0502-27

H Housing, Actuator, Brake 060602-N0502-27A

H Housing, Actuator, Brake 060602-N0502-27B



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Spring, Coil, Piston, Actuator, Br 060602-N0502-30
H Spring, Coil, Actuator, Brake 060602-N0502-31
H Snap Ring - Actuator, Brake 060602-N0502-32

H Nut, Lock, Actuator, Brake 060602-N0502-33
H C-Clip, Brake Actuator Piston **116 31.00**  9.00

**277 13.00**  0.25

**138 26.00**  1.00

**164 22.00**  1.00

**277 13.00**  0.25

**128 28.20**  2.00

**900 4.00**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H C-Clip, Brake Actuator Piston 060602-N0502-35

H Label, Brake Pedal Actuator Asm 060602-N0502-36
H Sensor, Pressure, Brake Pedal 060602-N0502-39
H Wire, Retaining, Plunger, Brake, Actuator 060602-N0502-38
H Ball, Plug, Stainless Steel, 3.4 mm 060602-N0502-28
H Coil, Magnetic, Brake Actuator 060602-N0502-29

H Fluid, Actuator, Brake 060602-N0502-37



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Piston, Actuator, Brake 060602-N0502-40 **2** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **277 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.07**  **$0.05 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.14 $0.27**  **$0.00**

2 H Piston, Actuator, Brake, Washed 060602-N0502-41 **2** Batch Wash T2/T3 Mech. Assembly, SSLC Aluminum-6061, Bar General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.050 **$1.50 $38.55**  **$10.75 $10.75**  **$0.08 $0.03**  **$0.04 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.16 $0.33**  **$0.15**

3 H Piston, Actuator, Brake, Washed 060602-N0502-41A **2** Pre cut Al 6061, bar, machined T2/T3 CNC Milling, SSLC Aluminum-6061, Bar CNC Operator DS-CNC Turning, SMS, BF,

DA **292 1**  **3 1**  0.050 **$1.50 $36.98**  **$27.76 $83.28**  **$0.08 $0.13**  **$0.29 $0.49**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.54 $1.07**  **$0.15**

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**



### 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**



### 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 H O-Ring, Piston, Actuator 060602-N0502-42 **2** S **$0.00** $0.08 **$0.00 $0.16**  **$0.16**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.46**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.84**

**T1 or OEM Total Manufacturing Cost: $0.46**  **$0.46 $0.76**  **$1.68 $0.00**  **$0.09 $0.06**  **$0.00 $0.16**  **$1.84**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.12**  **$0.11 $0.05**  **$0.28** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 

**Base Cost Impact to Vehicle: $0.46**  **$0.46 $0.76**  **$1.68 $0.01**  **$0.21 $0.17**  **$0.05 $0.44**  **$2.12 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.12** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

H Piston, Actuator, Brake 060602-N0502-40

H Piston, Actuator, Brake, Washed 060602-N0502-41

H Piston, Actuator, Brake, Washed 060602-N0502-41A



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H O-Ring, Piston, Actuator 060602-N0502-42 **$0.14 $0.11**  **$0.25 $0.00**  **$0.01 $0.01**  **$0.00 $0.03**  Press washer on to piston **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 13 1 1 13 **1.0 1.0** 

**$0.07 $0.08**  **$0.30 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 13 1 1 13 **1.0 1.0** 

**$0.25 $0.57**  **$0.97 $0.00**  **$0.06 $0.04**  **$0.00 $0.10**  TL-15 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 37 7 1 37 **1.0 3.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.16**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.46 $0.76**  **$1.68 $0.00**  **$0.09 $0.06**  **$0.00 $0.16** 

**$1.84 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Piston, Actuator, Brake 060602-N0502-40

H Piston, Actuator, Brake, Washed 060602-N0502-41

H Piston, Actuator, Brake, Washed 060602-N0502-41A



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H O-Ring, Piston, Actuator 060602-N0502-42 **277 13.00**  0.50

**277 13.00**  0.25

**292 12.33**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Cap, Piston Spring Asm 060602-N0502-43 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **360 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.04 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.00**

2 H Cap, Rim 060602-N0502-44 **1** Vertical Stamping Press, Tonnage 0-60 T2/T3 Stamp/Form, SSLC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.008 **$1.64 $42.73**  **$15.50 $15.50**  **$0.01 $0.00**  **$0.00 $0.02**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.02 $0.02**  **$0.01**

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**



### 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**



### 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 H Cap, Button 060602-N0502-45 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.04**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.16**

**T1 or OEM Total Manufacturing Cost: $0.04**  **$0.06 $0.04**  **$0.14 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  **$0.16**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 
**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.01**  **$0.01 $0.00**  **$0.02**

**Base Cost Impact to Vehicle: $0.04**  **$0.06 $0.04**  **$0.14 $0.00**  **$0.02 $0.01**  **$0.00 $0.04**  **$0.18 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.18** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

H Cap, Piston Spring Asm 060602-N0502-43

H Cap, Rim 060602-N0502-44



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Cap, Button 060602-N0502-45 **$0.05 $0.04**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Press washer on to piston **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 10 1 1 10 **1.00 1.0** 

**$0.00 $0.00**  **$0.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Progressive, 25 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.6 1 1 0.6 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.03**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.06 $0.04**  **$0.14 $0.00**  **$0.01 $0.00**  **$0.00 $0.01** 

**$0.16 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Cap, Piston Spring Asm 060602-N0502-43

H Cap, Rim 060602-N0502-44



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Cap, Button 060602-N0502-45 **360 10.00**  0.50

**6000 0.60**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Plunger Asm, Brake, Actuator 060602-N0502-46 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **277 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.03**  **$0.05 $0.09**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.10 $0.10**  **$0.00**

2 H Cap, Plunger, Actuator 060602-N0502-50 **1** Vertical Stamping Press, Tonnage 0-60 T2/T3 Stamp/Form, SSLC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.010 **$1.64 $42.73**  **$15.50 $15.50**  **$0.02 $0.00**  **$0.00 $0.02**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.02 $0.02**  **$0.02**

3 H Shaft, Actuator, Brake 060602-N0502-47 **1** Batch Wash T2/T3 Mech. Assembly, SSLC S-Steel-439, Bar General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.350 **$3.00 $38.55**  **$10.75 $10.75**  **$1.05 $0.03**  **$0.04 $1.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.12**  **$1.24 $1.24**  **$1.05**

4 H Shaft, Actuator, Brake 060602-N0502-47A **1** Pre cut bar, machined T2/T3 CNC Milling, SSLC S-Steel-439, Bar CNC Operator DS-CNC Turning, SMS, BF,

DA **176 0.5**  **2 1**  0.350 **$3.00 $36.98**  **$27.76 $55.52**  **$1.05 $0.11**  **$0.32 $1.47**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.15**  **$1.62 $1.62**  **$1.05**

5 H Bell Housing, Actuator, Brake 060602-N0502-48 **1** Batch Wash T2/T3 Mech. Assembly, SSLC Aluminum-6061, Bar General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.040 **$1.50 $38.55**  **$10.75 $10.75**  **$0.06 $0.03**  **$0.04 $0.13**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.15 $0.15**  **$0.06**

6 H Bell Housing, Actuator, Brake 060602-N0502-48A **1** Pre cut Al 6061, bar, machined T2/T3 CNC Milling, SSLC Aluminum-6061, Bar CNC Operator DS-CNC Turning, SMS, BF,

DA **176 0.5**  **2 1**  0.040 **$1.50 $36.98**  **$27.76 $55.52**  **$0.06 $0.11**  **$0.32 $0.48**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.53 $0.53**  **$0.06**

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**



### 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**



### 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 H Foam W iper, Actuator, Brake 060602-N0502-49 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

**$2.25**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$3.67**

**T1 or OEM Total Manufacturing Cost: $2.25**  **$0.32 $0.77**  **$3.33 $0.01**  **$0.20 $0.13**  **$0.00 $0.34**  **$3.67**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.02 $0.24**  **$0.22 $0.09**  **$0.57**

**Base Cost Impact to Vehicle: $2.25**  **$0.32 $0.77**  **$3.33 $0.03**  **$0.44 $0.35**  **$0.09 $0.91**  **$4.24 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $4.24**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447**  

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

H Plunger Asm, Brake, Actuator 060602-N0502-46

H Cap, Plunger, Actuator 060602-N0502-50

H Shaft, Actuator, Brake 060602-N0502-47

H Shaft, Actuator, Brake 060602-N0502-47A

H Bell Housing, Actuator, Brake 060602-N0502-48

H Bell Housing, Actuator, Brake 060602-N0502-48A



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Foam W iper, Actuator, Brake 060602-N0502-49 **$0.03 $0.05**  **$0.09 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Assemble bell housing, foam wiper, plunger cap and stud/o-ring to plunger **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 4 1 13 **1.00 1.0** 

**$0.00 $0.00**  **$0.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Progressive, 25 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.6 1 1 0.6 **1.0 1.0** 

**$0.03 $0.04**  **$1.12 $0.00**  **$0.07 $0.04**  **$0.00 $0.12**  Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.11 $0.32**  **$1.47 $0.00**  **$0.09 $0.06**  **$0.00 $0.15**  TL-15 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 41 8 1 41 **1.0 2.0** 

**$0.03 $0.04**  **$0.13 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.11 $0.32**  **$0.48 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  TL-15 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 41 8 1 41 **1.0 2.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.01**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.32 $0.77**  **$3.33 $0.01**  **$0.20 $0.13**  **$0.00 $0.34** 

**$3.67 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Plunger Asm, Brake, Actuator 060602-N0502-46

H Cap, Plunger, Actuator 060602-N0502-50

H Shaft, Actuator, Brake 060602-N0502-47

H Shaft, Actuator, Brake 060602-N0502-47A

H Bell Housing, Actuator, Brake 060602-N0502-48

H Bell Housing, Actuator, Brake 060602-N0502-48A



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Foam W iper, Actuator, Brake 060602-N0502-49 **277 13.00**  0.25

**6000 0.60**  0.50

**277 13.00**  0.25

**176 20.50**  0.50

**277 13.00**  0.25

**176 20.50**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Stud and O-Ring Asm, Actuator 060602-N0502-51 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **277 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.07**  **$0.05 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.14 $0.14**  **$0.00**

1 H Stud, Threaded, Actuator, Brake 060602-N0502-52 **1** Passivate & Wash T2/T3 Mech. Assembly, SSLC S-Steel-439, Bar General Assembly Washing Equipment, LC **157 0.25**  **1 1**  0.120 **$3.00 $38.55**  **$10.75 $10.75**  **$0.36 $0.06**  **$0.07 $0.49**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.54 $0.54**  **$0.36**

2 H Stud, Threaded, Actuator, Brake 060602-N0502-52A **1** Pre cut bar, machined T2/T3 CNC Milling, SSLC S-Steel-439, Bar CNC Operator DS-CNC Turning, SMS, BF,

DA **160 0.5**  **2 1**  0.120 **$3.00 $36.98**  **$27.76 $55.52**  **$0.36 $0.12**  **$0.35 $0.82**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.08**  **$0.91 $0.91**  **$0.36**

3 H Retainer, Plunger, Actuator, Brake 060602-N0502-54 **1** Pre cut bar, machined T2/T3 CNC Milling, SSLC S-Steel-439, Bar CNC Operator DS-CNC Turning, SMS, BF,

DA **129 0.5**  **1 1**  0.070 **$3.00 $36.98**  **$27.76 $27.76**  **$0.21 $0.14**  **$0.22 $0.57**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.63 $0.63**  **$0.21**

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**



### 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**



### 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 H O-Ring, Stud, Actuator, Brake 060602-N0502-53 **1** S **$0.00** $0.07 **$0.00 $0.07**  **$0.07**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$1.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$2.28** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

**1**

**T1 or OEM Total Manufacturing Cost: $1.00**  **$0.39 $0.69**  **$2.08 $0.01**  **$0.12 $0.08**  **$0.00 $0.21**  **$2.28**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.15**  **$0.14 $0.06**  **$0.35**

**Base Cost Impact to Vehicle: $1.00**  **$0.39 $0.69**  **$2.08 $0.02**  **$0.27 $0.22**  **$0.06 $0.56**  **$2.64 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.64**  **3** 

### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

H Stud and O-Ring Asm, Actuator 060602-N0502-51

H Stud, Threaded, Actuator, Brake 060602-N0502-52

H Stud, Threaded, Actuator, Brake 060602-N0502-52A

H Retainer, Plunger, Actuator, Brake 060602-N0502-54



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H O-Ring, Stud, Actuator, Brake 060602-N0502-53 **$0.07 $0.05**  **$0.12 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Press o-ring on to stud and swage retainer **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 2 1 13 **1.00 1.0** 

**$0.06 $0.07**  **$0.49 $0.00**  **$0.03 $0.02**  **$0.00 $0.05** 

Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 23 1 1 23 **1.0 1.0** 

**$0.12 $0.35**  **$0.82 $0.00**  **$0.05 $0.03**  **$0.00 $0.08**  TL-15 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 45 10 1 45 **1.0 2.0** 

**$0.14 $0.22**  **$0.57 $0.00**  **$0.03 $0.02**  **$0.00 $0.06**  TL-15 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 28 6 1 28 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.07**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.39 $0.69**  **$2.08 $0.01**  **$0.12 $0.08**  **$0.00 $0.21** 

**$2.28 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Stud and O-Ring Asm, Actuator 060602-N0502-51

H Stud, Threaded, Actuator, Brake 060602-N0502-52

H Stud, Threaded, Actuator, Brake 060602-N0502-52A

H Retainer, Plunger, Actuator, Brake 060602-N0502-54



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H O-Ring, Stud, Actuator, Brake 060602-N0502-53 **277 13.00**  0.50

**157 23.00**  0.25

**160 22.50**  0.50

**129 28.00**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Brake Pedal and Simulator Asm 060602-N0502-55 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **240 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.04**  **$0.06 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$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**



### 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**



### 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**

**Material**

**$0.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.11**

**T1 or OEM Total Manufacturing Cost: $0.00**  **$0.04 $0.06**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  **$0.11**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.01**  **$0.01 $0.00**  **$0.02**

**Base Cost Impact to Vehicle: $0.00**  **$0.04 $0.06**  **$0.10 $0.00**  **$0.01 $0.01**  **$0.00 $0.03**  **$0.13 $0**  **$0**

**Packaging Cost: $0.00**  

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.13** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

H Brake Pedal and Simulator Asm 060602-N0502-55



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.04**  **$0.06 $0.10**  **$0.00 $0.01**  **$0.00 $0.00**  **$0.01** Press simulator onto Brake Pedal Arm Subasm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 15 1 1 15 **1.00 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.04 $0.06**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01** 

**$0.11 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Brake Pedal and Simulator Asm 060602-N0502-55



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 240**  **15.00** 0.25

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Brake Pedal Arm, Subassembly 060602-N0502-56 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **212 0.5**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.09**  **$0.14 $0.23**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.26 $0.26**  **$0.00**

2 H Contact Cover, Brake Pedal 060602-N0502-59 **1** H Contact Cover, Brake Pedal, SBR ,mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, LS **182 0.5**  **1 1**  0.178 **$1.32 $41.48**  **$151.77 $151.77**  **$0.23 $0.11**  **$0.83 $1.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.12**  **$1.30 $1.30**  **$0.23**

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**



### 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**



### 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 H Bumper, Brake Pedal 060602-N0502-57 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

3 H Bushing, Brake Pedal Pivot 060602-N0502-58 **1** S **$0.00** $0.38 **$0.00 $0.38**  **$0.38**

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**

**Material**

**$0.62**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.95** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for

**1**

**T1 or OEM Total Manufacturing Cost: $0.62**  **$0.20 $0.97**  **$1.80 $0.00**  **$0.08 $0.06**  **$0.00 $0.15**  **$1.95**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.13**  **$0.12 $0.05**  **$0.30**

**Base Cost Impact to Vehicle: $0.62**  **$0.20 $0.97**  **$1.80 $0.01**  **$0.21 $0.17**  **$0.05 $0.45**  **$2.25 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.25**  **3** 

### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

H Brake Pedal Arm, Subassembly 060602-N0502-56

H Contact Cover, Brake Pedal 060602-N0502-59



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Bumper, Brake Pedal 060602-N0502-57
H Bushing, Brake Pedal Pivot 060602-N0502-58 **$0.09 $0.14**  **$0.23 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Attach brake pedal contact cover and bumper, insert bushinf into tube **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 34 3 1 34 **1.00 2.0** 

**$0.11 $0.83**  **$1.18 $0.00**  **$0.07 $0.05**  **$0.00 $0.12**  4 Cavity Mold, Box Size 125mm x 17mm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19.74 1 4 78.94 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.01**

**$0.38**

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.20 $0.97**  **$1.80 $0.00**  **$0.08 $0.06**  **$0.00 $0.15** 

**$1.95 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Brake Pedal Arm, Subassembly 060602-N0502-56

H Contact Cover, Brake Pedal 060602-N0502-59



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Bumper, Brake Pedal 060602-N0502-57
H Bushing, Brake Pedal Pivot 060602-N0502-58 **212 17.00**  0.50

**182 19.74**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Brake Pedal Arm, Weldment, Painted 060602-N0502-60 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **225 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.09**  **$0.07 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.17 $0.17**  **$0.00**

2 H Pin, Brake Pedal Spring Pivot 060602-N0502-62 **1** Wash T2/T3 Mech. Assembly, SSLC S-Steel-416, Bar General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.120 **$1.41 $38.55**  **$10.75 $10.75**  **$0.17 $0.03**  **$0.04 $0.24**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.27 $0.27**  **$0.17**

3 H Pin, Brake Pedal Spring Pivot 060602-N0502-62A **1** Pre cut S-Steel bar, machined T2/T3 CNC Milling, SSLC S-Steel-416, Bar CNC Operator CNC Turning, SS, BF, DA **450 0.5**  **1 1**  0.140 **$1.41 $36.98**  **$20.48 $20.48**  **$0.20 $0.04**  **$0.05 $0.28**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.31 $0.31**  **$0.20**

4 H Bar, Brake Pedal Spring 060602-N0502-64 **1** Wash T2/T3 Mech. Assembly, SSLC MC-Steel-1018, Bar General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.74 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

5 H Bar, Brake Pedal Spring 060602-N0502-64A **1** Machine T2/T3 CNC Turning, SSLC MC-Steel-1018, Bar CNC Operator CNC Machining, LC **327 0.5**  **1 1**  0.000 **$0.74 $36.98**  **$30.38 $30.38**  **$0.00 $0.06**  **$0.09 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.16 $0.16**  **$0.00**

6 H Bar, Brake Pedal Spring 060602-N0502-64B **1** Forge bar stock to shape T2/T3 Forge, SSLC MC-Steel-1018, Bar Forging Operator Forge, SS **144 1**  **1 1**  0.313 **$0.74 $40.18**  **$115.72 $115.72**  **$0.23 $0.28**  **$0.80 $1.31**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.14**  **$1.45 $1.45**  **$0.23**

7 H Bracket, Brake Pedal Stop 060602-N0502-65 **1** Vertical Stamping Press, Tonnage 0-60 T2/T3 Stamp/Form, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.229 **$0.55 $42.73**  **$15.50 $15.50**  **$0.13 $0.00**  **$0.00 $0.13**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.15 $0.15**  **$0.13**

8 H Pedal Contact, Brake Pedal 060602-N0502-66 **1** Vertical Stamping Press, Tonnage 0-60 T2/T3 Stamp/Form, SSLC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.398 **$0.48 $42.73**  **$15.50 $15.50**  **$0.19 $0.00**  **$0.00 $0.20**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.22 $0.22**  **$0.19**

9 H Brake Pedal Arm, Partial W eldment 060602-N0502-61 **1** Paint Part T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **300 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.03**  **$0.05 $0.08**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.09 $0.09**  **$0.00**

10 H Brake Pedal Arm, Partial W eldment 060602-N0502-61A **1** Wash T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil General Assembly Washing Equipment, LMC **277 0.25**  **1 1**  0.000 **$0.48 $38.55**  **$20.81 $20.81**  **$0.00 $0.03**  **$0.08 $0.11**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.12 $0.12**  **$0.00**

11 H Brake Pedal Arm, Partial W eldment 060602-N0502-61B **1** Final Welding T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil Welding/Soldering Operator Mech. Assembly, LC **176 0.25**  **2 1**  0.000 **$0.48 $41.55**  **$100.00 $200.00**  **$0.00 $0.06**  **$1.14 $1.20**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.12**  **$1.32 $1.32**  **$0.00**

12 H Brake Pedal Arm, Partial W eldment 060602-N0502-61C **1** Final Machining T2/T3 CNC Turning, SSLC LC-GSteel-1000S, Coil CNC Operator CNC Machining, LMC **138 0.5**  **1 1**  0.000 **$0.48 $36.98**  **$34.48 $34.48**  **$0.00 $0.13**  **$0.25 $0.38**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.42 $0.42**  **$0.00**

13 H Brake Pedal Arm, Partial W eldment 060602-N0502-61D **1** Initial Welding T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil Welding/Soldering Operator Mech. Assembly, LC **180 0.25**  **1 1**  0.000 **$0.48 $41.55**  **$100.00 $100.00**  **$0.00 $0.06**  **$0.56 $0.61**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.68 $0.68**  **$0.00**

14 H Brake Pedal Arm, Partial W eldment 060602-N0502-61E **1** Press & Swaging T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil General Assembly Mech. Assembly, LC **225 1**  **1 1**  0.000 **$0.48 $38.55**  **$100.00 $100.00**  **$0.00 $0.17**  **$0.44 $0.62**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.68 $0.68**  **$0.00**

15 H Brake Pedal Arm, Partial W eldment 060602-N0502-61F **1** Initial Machining T2/T3 CNC Turning, SSLC LC-GSteel-1000S, Coil CNC Operator CNC Machining, LMC **113 0.5**  **1 1**  0.000 **$0.48 $36.98**  **$34.48 $34.48**  **$0.00 $0.16**  **$0.31 $0.47**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.52 $0.52**  **$0.00**

16 H Brake Pedal Arm, Partial W eldment 060602-N0502-61G **1** Stamp T2/T3 Stamp/Form, MSMC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS **2000 0.5**  **1 1**  10.620 **$0.48 $42.73**  **$60.65 $60.65**  **$5.10 $0.01**  **$0.03 $5.14**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.72**  **$5.86 $5.86**  **$5.10**

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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**
**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 H Tube, Pivot, Brake Pedal Arm 060602-N0502-63 **1** S **$0.00** $0.11 **$0.00 $0.11**  **$0.11**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$6.12**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$12.61**

**T1 or OEM Total Manufacturing Cost: $6.12**  **$1.20 $3.94**  **$11.27 $0.04**  **$0.70 $0.55**  **$0.05 $1.34**  **$12.61**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.**  **T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.06 $0.82**  **$0.76 $0.32**  **$1.95**

**Base Cost Impact to Vehicle: $6.12**  **$1.20 $3.94**  **$11.27 $0.11**  **$1.51 $1.31**  **$0.37 $3.29**  **$14.56 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $14.56** 

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

H Brake Pedal Arm, Weldment, Painted 060602-N0502-60

H Pin, Brake Pedal Spring Pivot 060602-N0502-62

H Pin, Brake Pedal Spring Pivot 060602-N0502-62A

H Bar, Brake Pedal Spring 060602-N0502-64
H Bar, Brake Pedal Spring 060602-N0502-64A

H Bar, Brake Pedal Spring 060602-N0502-64B

H Bracket, Brake Pedal Stop 060602-N0502-65

H Pedal Contact, Brake Pedal 060602-N0502-66

H Brake Pedal Arm, Partial W eldment 060602-N0502-61

H Brake Pedal Arm, Partial W eldment 060602-N0502-61A

H Brake Pedal Arm, Partial W eldment 060602-N0502-61B

H Brake Pedal Arm, Partial W eldment 060602-N0502-61C

H Brake Pedal Arm, Partial W eldment 060602-N0502-61D

H Brake Pedal Arm, Partial W eldment 060602-N0502-61E

H Brake Pedal Arm, Partial W eldment 060602-N0502-61F

H Brake Pedal Arm, Partial W eldment 060602-N0502-61G **$0.09 $0.07**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Insert and swage pin and tube **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 16 3 1 16 **1.00 1.0** 

**$0.03 $0.04**  **$0.24 $0.00**  **$0.01 $0.01**  **$0.00 $0.03** 

Washer Duo 400 Wash Rinse & Dry, batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.04 $0.05**  **$0.28 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  SL-10 turning 1.75" Bar, 2 axis **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9 5 1 8 **1.0 1.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  Batch Wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.06 $0.09**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  EC- 300-Ml **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0** 

**$0.28 $0.80**  **$1.31 $0.00**  **$0.08 $0.05**  **$0.00 $0.14**  InductcoForge , 3 Module Induction forge heating equipmentheating Erie Mechanical Press, 500T, KASTCO circular saw cut off tool with bundle unscrammbler, chip conveyor & discharge conveyer. **5 1**  **7.2 36**  **48 1728**  **266 13.54**  **85% 313**  **11.51**

- - 1 25 **1.0 1.0** 

**$0.00 $0.00**  **$0.13 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.20 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  25 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.6 1 1 0.6 **1.0 1.0** 

**$0.03 $0.05**  **$0.08 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  Dipped/air dryed **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12 1 1 12 **1.0 1.0** 

**$0.03 $0.08**  **$0.11 $0.00**  **$0.01 $0.00**  **$0.00 $0.01** 

In line Washer Turbo Tunnel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.06 $1.14**  **$1.20 $0.00**  **$0.07 $0.05**  **$0.00 $0.12**  Arc weld - brake pedal stop and bracket to arm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 41 4 1 41 **1.0 2.0** 

**$0.13 $0.25**  **$0.38 $0.00**  **$0.02 $0.02**  **$0.00 $0.04**  EC-400-ML Turnng - Final machining - cut pivot to length, mill face/chamfer inner and outer diameter **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 26 5 1 26 **1.0 1.0** 

**$0.06 $0.56**  **$0.61 $0.00**  **$0.04 $0.02**  **$0.00 $0.06**  Spot projection weld auto load - brake stop bar to arm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 20 2 1 20 **1.0 1.0** 

**$0.17 $0.44**  **$0.62 $0.00**  **$0.04 $0.02**  **$0.00 $0.06**  Press/Swage barke pedal sping pin and tube to arm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 16 3 1 16 **1.0 1.0** 

**$0.16 $0.31**  **$0.47 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  EC-400-ML Turnng - Initial machining - holes in arm **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 32 8 1 32 **1.0 1.0** 

**$0.01 $0.03**  **$5.14 $0.03**  **$0.33 $0.31**  **$0.05 $0.72**  300 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 1 1.8 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Tube, Pivot, Brake Pedal Arm 060602-N0502-63 

### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00**

**$0.11**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$1.20 $3.94**  **$11.27 $0.04**  **$0.70 $0.55**  **$0.05 $1.34** 

**$12.61 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.**  **a) Items 1,2, & 3 must all equal same**  **otherwise there is a computation** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Brake Pedal Arm, Weldment, Painted 060602-N0502-60

H Pin, Brake Pedal Spring Pivot 060602-N0502-62

H Pin, Brake Pedal Spring Pivot 060602-N0502-62A

H Bar, Brake Pedal Spring 060602-N0502-64
H Bar, Brake Pedal Spring 060602-N0502-64A

H Bar, Brake Pedal Spring 060602-N0502-64B

H Bracket, Brake Pedal Stop 060602-N0502-65

H Pedal Contact, Brake Pedal 060602-N0502-66

H Brake Pedal Arm, Partial W eldment 060602-N0502-61

H Brake Pedal Arm, Partial W eldment 060602-N0502-61A

H Brake Pedal Arm, Partial W eldment 060602-N0502-61B

H Brake Pedal Arm, Partial W eldment 060602-N0502-61C

H Brake Pedal Arm, Partial W eldment 060602-N0502-61D

H Brake Pedal Arm, Partial W eldment 060602-N0502-61E

H Brake Pedal Arm, Partial W eldment 060602-N0502-61F

H Brake Pedal Arm, Partial W eldment 060602-N0502-61G **225 16.00**  0.50

**277 13.00**  0.25

**450 8.00**  0.50

**277 13.00**  0.25

**327 11.00**  0.50

**144 25.00**  1.00

**5143 0.70**  0.50

**6000 0.60**  0.50

**300 12.00**  0.25

**277 13.00**  0.25

**176 20.50**  0.25

**138 26.00**  0.50

**180 20.00**  0.25

**225 16.00**  1.00

**113 32.00**  0.50

**2000 1.80**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) #DIV/0!**  **#DIV/0!**

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

H Tube, Pivot, Brake Pedal Arm 060602-N0502-63**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Simulator, Brake Pedal Asm 060602-N0502-67 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **144 2**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.54**  **$0.21 $0.75**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.08**  **$0.82 $0.82**  **$0.00**

2 H Bumper, Leaf Spring, Simulator 060602-N0502-68 **1** H Bumper, Leaf Spring,mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **390 0.5**  **1 1**  0.006 **$0.99 $41.48**  **$16.39 $16.39**  **$0.01 $0.05**  **$0.04 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.01**

3 H Cover, Simulator, Brake Pedal 060602-N0502-69 **1** Electroplate T2/T3 Plate/Finish Mech.,

SSLC LC-GSteel-1000S, Coil Plating/Coating Operator Plate/Finish, SMS, MHC **184 0.25**  **0.5 1**  0.000 **$0.48 $40.84**  **$125.00 $62.50**  **$0.00 $0.06**  **$0.34 $0.40**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.44 $0.44**  **$0.00**

4 H Cover, Simulator, Brake Pedal 060602-N0502-69A **1** Wash T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil CNC Operator Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.48 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

5 H Cover, Simulator, Brake Pedal 060602-N0502-69B **1** Debur T2/T3 CNC Turning, SSLC LC-GSteel-1000S, Coil 

### Grinding/Polishing Grinding, SS **327 0.25**  **1 1**  0.000 **$0.48 $42.14**  **$45.00 $45.00**  **$0.00 $0.03**  **$0.14 $0.17**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.19 $0.19**  **$0.00**

6 H Cover, Simulator, Brake Pedal 060602-N0502-69C **1** Vertical Stamping Press, Tonnage 0-60 T2/T3 Stamp/Form, SSLC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.387 **$0.48 $42.73**  **$15.50 $15.50**  **$0.19 $0.00**  **$0.00 $0.19**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.21 $0.21**  **$0.19**

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**



### 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**



### 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 H Screw, Cover, Brake Pedal Spring, Primary 060602-N0502-70 **2** S **$0.00** $0.05 **$0.00 $0.10**  **$0.10**

3 H O-Ring, NVH, Simulator Shaft 060602-N0502-71 **3** S **$0.00** $0.005 **$0.00 $0.02**  **$0.02** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 3 H O-Ring, NVH, Simulator Shaft 060602-N0502-71 **3** S **$0.00** $0.005 **$0.00 $0.02**  **$0.02**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.31**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.96**

**T1 or OEM Total Manufacturing Cost: $0.31**  **$0.71 $0.77**  **$1.79 $0.01**  **$0.10 $0.07**  **$0.00 $0.17**  **$1.96**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% 

### "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

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.13**  **$0.12 $0.05**  **$0.30**

**Base Cost Impact to Vehicle: $0.31**  **$0.71 $0.77**  **$1.79 $0.01**  **$0.23 $0.18**  **$0.05 $0.48**  **$2.27 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.27** 

**Packaging Cost per**  **Total Lump Sum**  **Payment Total # of**  **Number of Interest** **C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ R** **a c** **k S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years **Cost per**

**Piece Total** 

**Amount Payment** 

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Parts/Layer: Number of Layers: Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

H Simulator, Brake Pedal Asm 060602-N0502-67

H Bumper, Leaf Spring, Simulator 060602-N0502-68

H Cover, Simulator, Brake Pedal 060602-N0502-69

H Cover, Simulator, Brake Pedal 060602-N0502-69A

H Cover, Simulator, Brake Pedal 060602-N0502-69B

H Cover, Simulator, Brake Pedal 060602-N0502-69C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Screw, Cover, Brake Pedal Spring, Primary 060602-N0502-70

H O-Ring, NVH, Simulator Shaft 060602-N0502-71 **$0.54 $0.21**  **$0.75 $0.00**  **$0.04 $0.03**  **$0.00 $0.08**  2 station 2 operator, Place O-rings into housings openings attcah bumper to leaf spring asm , rubber spring and attach cover to housing with two screws. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 50.1 10 1 50.1 **1.00 2.0** 

**$0.05 $0.04**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  16 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9.24 1 16 147.84 **1.0 1.0** 

**$0.06 $0.34**  **$0.40 $0.00**  **$0.02 $0.02**  **$0.00 $0.04** 

Zinc Plating, Batched Processed **1 1**  **10 10**  **47 470**  **957 3.76**  **85% 1126**  **3.20** 9.8 1 1 9.8 **1.0 0.5** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 

Batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.03 $0.14**  **$0.17 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Tumble **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0** 

**$0.00 $0.00**  **$0.19 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.10**

**$0.02** H O-Ring, NVH, Simulator Shaft 060602-N0502-71

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.71 $0.77**  **$1.79 $0.01**  **$0.10 $0.07**  **$0.00 $0.17** 

**$1.96 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Simulator, Brake Pedal Asm 060602-N0502-67

H Bumper, Leaf Spring, Simulator 060602-N0502-68

H Cover, Simulator, Brake Pedal 060602-N0502-69

H Cover, Simulator, Brake Pedal 060602-N0502-69A

H Cover, Simulator, Brake Pedal 060602-N0502-69B

H Cover, Simulator, Brake Pedal 060602-N0502-69C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Screw, Cover, Brake Pedal Spring, Primary 060602-N0502-70

H O-Ring, NVH, Simulator Shaft 060602-N0502-71 **144 25.05**  2.00

**390 9.24**  0.50

**184 19.60**  0.25

**277 13.00**  0.25

**327 11.00**  0.25

**5143 0.70**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H O-Ring, NVH, Simulator Shaft 060602-N0502-71



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Spring, Leaf, Simulator Asm 060602-N0502-72 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **189 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.10**  **$0.08 $0.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.20 $0.20**  **$0.00**

2 H Pad, Leaf Spring, Leaf 060602-N0502-74 **1** H Pad, Leaf Spring ,mold T2/T3 Inject. Mold, SSLC Nylon6, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **759 0.5**  **1 1**  0.064 **$1.65 $41.48**  **$16.39 $16.39**  **$0.11 $0.03**  **$0.02 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.17 $0.17**  **$0.11**

3 H Pad #2, Leaf Spring, Leaf 060602-N0502-75 **1** H Pad #2, Leaf Spring ,mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **5263 0.5**  **1 1**  0.002 **$1.54 $41.48**  **$16.39 $16.39**  **$0.00 $0.00**  **$0.00 $0.01**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.01 $0.01**  **$0.00**

4 H Spring, Leaf, Simulator 060602-N0502-73 **1** Electroplate T2/T3 Plate/Finish Mech.,

SSLC LC-GSteel-1000S, Coil Plating/Coating Operator Plate/Finish, SMS, MHC **184 0.25**  **0.5 1**  0.000 **$0.48 $40.84**  **$125.00 $62.50**  **$0.00 $0.06**  **$0.34 $0.40**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.44 $0.44**  **$0.00**

5 H Spring, Leaf, Simulator 060602-N0502-73A **1** Wash T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil CNC Operator Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.48 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

6 H Spring, Leaf, Simulator 060602-N0502-73B **1** Deburr T2/T3 CNC Turning, SSLC LC-GSteel-1000S, Coil 

### Grinding/Polishing Grinding, SS **327 0.25**  **1 1**  0.000 **$0.48 $42.14**  **$45.00 $45.00**  **$0.00 $0.03**  **$0.14 $0.17**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.19 $0.19**  **$0.00**

7 H Spring, Leaf, Simulator 060602-N0502-73C **1** Vertical Stamping Press, Tonnage 0-60 T2/T3 Stamp/Form, SSLC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.150 **$0.48 $42.73**  **$15.50 $15.50**  **$0.07 $0.00**  **$0.00 $0.08**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.09 $0.09**  **$0.07**

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**



### 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**



### 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** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly. 2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.18**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.17**

**T1 or OEM Total Manufacturing Cost: $0.18**  **$0.26 $0.62**  **$1.06 $0.00**  **$0.06 $0.04**  **$0.00 $0.11**  **$1.17**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.08**  **$0.07 $0.03**  **$0.18** 

### Assembly.

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Base Cost Impact to Vehicle: $0.18**  **$0.26 $0.62**  **$1.06 $0.01**  **$0.14 $0.11**  **$0.03 $0.29**  **$1.35 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.35** 

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **Reference Packaging Database for Additonal Infromation** Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike**C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Number of Layers: Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

H Spring, Leaf, Simulator Asm 060602-N0502-72

H Pad, Leaf Spring, Leaf 060602-N0502-74

H Pad #2, Leaf Spring, Leaf 060602-N0502-75

H Spring, Leaf, Simulator 060602-N0502-73

H Spring, Leaf, Simulator 060602-N0502-73A

H Spring, Leaf, Simulator 060602-N0502-73B

H Spring, Leaf, Simulator 060602-N0502-73C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.10**  **$0.08 $0.18**  **$0.00 $0.01**  **$0.01 $0.00**  **$0.02** Place Pads onto each end of leaf spring **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 19 1 1 19 **1.0 1.0** 

**$0.03 $0.02**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  8 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4.74 1 8 37.92 **1.0 1.0** 

**$0.00 $0.00**  **$0.01 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  8 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.684 1 8 5.47 **1.0 1.0** 

**$0.06 $0.34**  **$0.40 $0.00**  **$0.02 $0.02**  **$0.00 $0.04** 

Zinc Plating, Batched Processed **1 1**  **10 10**  **47 470**  **957 3.76**  **85% 1126**  **3.20** 9.8 1 1 9.8 **1.0 0.5** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 

Batch wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.03 $0.14**  **$0.17 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Tumble **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0** 

**$0.00 $0.00**  **$0.08 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.26 $0.62**  **$1.06 $0.00**  **$0.06 $0.04**  **$0.00 $0.11** 

**$1.17 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Spring, Leaf, Simulator Asm 060602-N0502-72

H Pad, Leaf Spring, Leaf 060602-N0502-74

H Pad #2, Leaf Spring, Leaf 060602-N0502-75

H Spring, Leaf, Simulator 060602-N0502-73

H Spring, Leaf, Simulator 060602-N0502-73A

H Spring, Leaf, Simulator 060602-N0502-73B

H Spring, Leaf, Simulator 060602-N0502-73C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 189**  **19.00** 0.50

**759 4.74**  0.50

**5263 0.68**  0.50

**184 19.60**  0.25

**277 13.00**  0.25

**327 11.00**  0.25

**5143 0.70**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Spring, Rubber Bumper, Plate Asm 060602-N0502-88 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **225 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.04**  **$0.07 $0.11**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.12 $0.12**  **$0.00**

2
H Spring, Rubber Bumper 060602-N0502-76 **1** H Bumper, Leaf Spring,mold T2/T3 Inject. Mold, SSLC Thermoset-EPDM Mold/Cast/Sinter Operator Inject. Mold, SS **132 2**  **5 1**  0.065 **$1.83 $41.48**  **$16.39 $81.95**  **$0.12 $0.63**  **$0.62 $1.37**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.14**  **$1.51 $1.51**  **$0.12**

3 H Plate, Spring, Rubber Bumper 060602-N0502-77 **1** Vertical Stamping Press, Tonnage 0-60 T2/T3 Stamp/Form, SSLC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **60000 0.5**  **1 1**  0.006 **$0.48 $42.73**  **$42.91 $42.91**  **$0.00 $0.00**  **$0.00 $0.00**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.00 $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**



### 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**



### 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**

**Material**

**$0.12**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$1.63** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

**1**

**T1 or OEM Total Manufacturing Cost: $0.12**  **$0.67 $0.69**  **$1.48 $0.00**  **$0.09 $0.06**  **$0.00 $0.15**  **$1.63**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.11**  **$0.10 $0.04**  **$0.25**

**Base Cost Impact to Vehicle: $0.12**  **$0.67 $0.69**  **$1.48 $0.01**  **$0.19 $0.16**  **$0.04 $0.41**  **$1.89 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.89**  **3** 

### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

H Spring, Rubber Bumper, Plate Asm 060602-N0502-88

H Spring, Rubber Bumper 060602-N0502-76

H Plate, Spring, Rubber Bumper 060602-N0502-77



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.04**  **$0.07 $0.11**  **$0.00 $0.01**  **$0.00 $0.00**  **$0.01** Place together - no adhesive **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 16 1 1 16 **1.00 1.0** 

**$0.63 $0.62**  **$1.37 $0.00**  **$0.08 $0.05**  **$0.00 $0.14**  16 Cavity Mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 136.20 1 16 2,179.2 **1.0 5.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.06 1 1 0.06 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$0.67 $0.69**  **$1.48 $0.00**  **$0.09 $0.06**  **$0.00 $0.15** 

**$1.63 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Spring, Rubber Bumper, Plate Asm 060602-N0502-88

H Spring, Rubber Bumper 060602-N0502-76

H Plate, Spring, Rubber Bumper 060602-N0502-77



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 225**  **16.00** 0.25

**132 27.24**  2.00

**60000 0.06**  0.50

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping) **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 H Housing Asm., Simulator, Brake Pedal 060602-N0502-78 **1** Assembly T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **160 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.24**  **$0.19 $0.43**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.47 $0.47**  **$0.00**

2 H Housing , Simulator, Brake Pedal 060602-N0502-79 **1** 1 Wash Cycles thru machining T2/T3 Mech. Assembly, SSLC Aluminum-A380, Cast CNC Operator Washing Equipment, LC **360 0.25**  **1 1**  0.000 **$1.10 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.03 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.06 $0.06**  **$0.00**

3 H Housing , Simulator, Brake Pedal 060602-N0502-79A **1** Machine T2/T3 CNC Milling, SSLC Aluminum-A380, Cast CNC Operator CNC Machining, MC **115 2**  **3 1**  0.000 **$1.10 $36.98**  **$45.37 $136.11**  **$0.00 $0.64**  **$1.18 $1.83**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.19**  **$2.02 $2.02**  **$0.00**

4 H Housing , Simulator, Brake Pedal 060602-N0502-79B **1** Heat Treat T2/T3 Heat Treat, SSLC Aluminum-A380, Cast Heat Treat Operator T5-Al380, SMS **180 1.5**  **1 1**  0.956 **$0.01 $47.72**  **$10.17 $10.17**  **$0.01 $0.40**  **$0.06 $0.47**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.51 $0.51**  **$0.01**

5 H Housing , Simulator, Brake Pedal 060602-N0502-79C **1** Housing-Cast T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MLS **364 1**  **1 1.1**  0.956 **$1.10 $41.48**  **$247.89 $272.68**  **$1.05 $0.11**  **$0.75 $1.91**  **5.00% 6.00%**  **4.00% 0.00%**  **15.00% $0.29**  **$2.20 $2.20**  **$1.05**

6 H Pin, Simulator - Actuator 060602-N0502-80 **1** Electroplate T2/T3 Plate/Finish Mech.,

SSLC HC-Steel-1000S, Coil Plating/Coating Operator Plate/Finish, SMS, MHC **184 0.25**  **0.5 1**  0.000 **$0.65 $40.84**  **$125.00 $62.50**  **$0.00 $0.06**  **$0.34 $0.40**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.44 $0.44**  **$0.00**

7 H Pin, Simulator - Actuator 060602-N0502-80A **1** 1 Wash Cycles thru machining T2/T3 Mech. Assembly, SSLC HC-Steel-1000S, Coil CNC Operator Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.65 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

8 H Pin, Simulator - Actuator 060602-N0502-80B **1** Machine T2/T3 CNC Milling, SSLC HC-Steel-1000S, Coil CNC Operator CNC Turning, SS, BF, DA **277 1**  **1 1**  0.000 **$0.65 $36.98**  **$20.48 $20.48**  **$0.00 $0.13**  **$0.07 $0.21**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.23 $0.23**  **$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**



### 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**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**
**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 H Pin, Dowel, Split, Simulator Housing 060602-N0502-81 **2** S **$0.00** $0.06 **$0.00 $0.12**  **$0.12**

2 H Bushing, Brake Simulator Housing 060602-N0502-82 **2** S **$0.00** $0.14 **$0.00 $0.28**  **$0.28** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly. 2 H Bushing, Brake Simulator Housing 060602-N0502-82 **2** S **$0.00** $0.14 **$0.00 $0.28**  **$0.28**

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**

**Material**

**$1.46**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$6.41**

**T1 or OEM Total Manufacturing Cost: $1.46**  **$1.64 $2.66**  **$5.77 $0.11**  **$0.32 $0.21**  **$0.00 $0.64**  **$6.41** 

### Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.03 $0.42**  **$0.38 $0.16**  **$0.99**

**Base Cost Impact to Vehicle: $1.46**  **$1.64 $2.66**  **$5.77 $0.14**  **$0.74 $0.60**  **$0.16 $1.64**  **$7.40 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $7.40** **C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) **Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Part Size: Parts/Layer: Number of Layers: Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

H Housing Asm., Simulator, Brake Pedal 060602-N0502-78

H Housing , Simulator, Brake Pedal 060602-N0502-79

H Housing , Simulator, Brake Pedal 060602-N0502-79A
H Housing , Simulator, Brake Pedal 060602-N0502-79B
H Housing , Simulator, Brake Pedal 060602-N0502-79C

H Pin, Simulator - Actuator 060602-N0502-80

H Pin, Simulator - Actuator 060602-N0502-80A

H Pin, Simulator - Actuator 060602-N0502-80B



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Pin, Dowel, Split, Simulator Housing 060602-N0502-81

H Bushing, Brake Simulator Housing 060602-N0502-82 **$0.24 $0.19**  **$0.43 $0.00**  **$0.03 $0.02**  **$0.00 $0.04**  Press on bushings and dowel pins **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 45 4 1 45 **1.00 2.0** 

**$0.03 $0.03**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  Washer Duo 400 Wash Rinse & Dry **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 5 1 10 **1.0 1.0** 

**$0.64 $1.18**  **$1.83 $0.01**  **$0.11 $0.07**  **$0.00 $0.19**  EC-500-ML Horizontal CNC **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 94 22 1 94 **1.0 3.0** 

**$0.40 $0.06**  **$0.47 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  T5 Heat Treat **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 1,350 27,000 **1.0 1.0** 

**$0.11 $0.75**  **$1.91 $0.10**  **$0.11 $0.08**  **$0.00 $0.29**  1.1 Multiplier used for trimming, + 2 seconds - cast with pin **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9.88 2 4 40 **1.1 1.0** 

**$0.06 $0.34**  **$0.40 $0.00**  **$0.02 $0.02**  **$0.00 $0.04** 

Zinc Plating, Batched Processed **1 1**  **10 10**  **47 470**  **957 3.76**  **85% 1126**  **3.20** 9.8 1 1 9.8 **1.0 0.5** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  Washer Duo 400 Wash Rinse & Dry **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.13 $0.07**  **$0.21 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  SL-10 auto feed **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 7 1 13 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.12**

**$0.28** H Bushing, Brake Simulator Housing 060602-N0502-82

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$1.64 $2.66**  **$5.77 $0.11**  **$0.32 $0.21**  **$0.00 $0.64** 

**$6.41 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Housing Asm., Simulator, Brake Pedal 060602-N0502-78

H Housing , Simulator, Brake Pedal 060602-N0502-79

H Housing , Simulator, Brake Pedal 060602-N0502-79A
H Housing , Simulator, Brake Pedal 060602-N0502-79B
H Housing , Simulator, Brake Pedal 060602-N0502-79C

H Pin, Simulator - Actuator 060602-N0502-80

H Pin, Simulator - Actuator 060602-N0502-80A

H Pin, Simulator - Actuator 060602-N0502-80B



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database)**

H Pin, Dowel, Split, Simulator Housing 060602-N0502-81

H Bushing, Brake Simulator Housing 060602-N0502-82 **160 22.50**  1.00

**360 10.00**  0.25

**115 31.33**  2.00

**180 20.00**  1.50

**364 9.88**  1.00

**184 19.60**  0.25

**277 13.00**  0.25

**277 13.00**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

H Bushing, Brake Simulator Housing 060602-N0502-82



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

# H Coil, Magnetic, Brake Actuator 

# ITT

used in the production of an automobile anti-lock breaking system (ABS). It consists of a bobbin molded of plastic material with copper wire wound around the bobbin to form an electrical coil. The bobbin is encased in a steel can which contains electrical pin connectors. When subjected to an electrical charge, this coil assembly builds up a magnetic field that moves a valve in the hydraulic circuit of the ABS system.

Copper Wire 

# 0.25

Bobbin 

# 0.15

Steel case 

# 1.25

Cap 

# 0.50

Pin connector 

# 0.75

Spring 

# 0.05

ring 

# 0.10

Metal sleeve 

# 0.30

Pole 

# 0.30

Assembly 

# 1.00

Total 

# 4.65

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

3 H Housing , Actuator, Brake 060602-N0502-27 **1** T2/T3 Mech. Assembly, SSLC Aluminum-A380, Cast CNC Operator Washing Equipment, LC **360 0.25**  **1 1**  0.000 **$1.10 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.03 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.06 $0.06**  **$0.00** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

3 H Housing , Actuator, Brake 060602-N0502-27 **1** 1 Wash Cycles thru machining T2/T3 Mech. Assembly, SSLC **360 0.25**  **1 1**  0.000 **$1.10 $36.98**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.03 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.06 $0.06**  **$0.00**

4 H Housing , Actuator, Brake 060602-N0502-27A **1** Machine T2/T3 CNC Milling, SSLC Aluminum-A380, Cast CNC Operator CNC Machining, MC **38 1**  **1 1**  0.000 **$1.10 $36.98**  **$45.37 $45.37**  **$0.00 $0.97**  **$1.18 $2.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.22**  **$2.37 $2.37**  **$0.00**

5 H Housing , Actuator, Brake 060602-N0502-27B **1** Heat Treat T2/T3 Heat Treat, SSLC Aluminum-A380, Cast Heat Treat Operator T5-Al380, SMS **585 1.5**  **1 1**  0.750 **$0.01 $47.72**  **$10.17 $10.17**  **$0.01 $0.12**  **$0.02 $0.15**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.16 $0.16**  **$0.01**

6 H Housing , Actuator, Brake 060602-N0502-27C **1** Housing-Cast T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MLS **364 1**  **1 1.1**  0.750 **$1.10 $41.48**  **$247.89 $272.68**  **$0.83 $0.11**  **$0.75 $1.69**  **5.00% 6.00%**  **4.00% 0.00%**  **15.00% $0.25**  **$1.94 $1.94**  **$0.83**

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**



### 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**



### 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**

**Material**

**$0.83**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total $4.54**  

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

**1 Material**  **Labor Burden**  **TMC Scrap**  **SG&A Profit**  **ED&T Total**  **Mark-up $4.54** 

**T1 or OEM Total Manufacturing Cost: $0.83**  **$1.23 $1.98**  **$4.04 $0.09**  **$0.24 $0.16**  **$0.00 $0.50**  **$4.54**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

**(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.02 $0.29**  **$0.27 $0.11**  **$0.70**

**Base Cost Impact to Vehicle: $0.83**  **$1.23 $1.98**  **$4.04 $0.11**  **$0.54 $0.43**  **$0.11 $1.20**  **$5.24 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $5.24**  **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" 

### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:
**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Brake Pedal Assembly**  

## Part Number: **060602-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material
**Cost $/lb**  **(DB) Labor** 
**Rate $/Hour**  **(DB) Burden** 
**Rate $/Hour**  **(DB) Applied** 
**Burden**
**Rate $/Hour**  **Material**

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap** 

**Rate (DB)**  **SG&A**

**Rate (DB)**  **Profit**

**Rate (DB)**  **ED&T/**
**R&D**

**Rate (DB)**  **Total**

**Mark**

**up Rate**  **Total**

**Mark**

**up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 
**450,000**

**1**
**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per** 

**Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per** 

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack** 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.)
Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0


### Packaging Cost Total: **$0.000** 

### Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

H Housing , Actuator, Brake 060602-N0502-27



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.03 $0.03**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 5 1 10 **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

H Housing , Actuator, Brake 060602-N0502-27

H Housing , Actuator, Brake 060602-N0502-27A

H Housing , Actuator, Brake 060602-N0502-27B

H Housing , Actuator, Brake 060602-N0502-27C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.03**  **$0.03 $0.06**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.01** Washer Duo 400 Wash Rinse & Dry **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 5 1 10 **1.0 1.0** 

**$0.97 $1.18**  **$2.15 $0.01**  **$0.13 $0.09**  **$0.00 $0.22**  EC-500-ML Horizontal CNC **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 94 22 1 94 **1.0 1.0** 

**$0.12 $0.02**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  T5 Heat Treat **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- - 4,390 27,000 **1.0 1.0** 

**$0.11 $0.75**  **$1.69 $0.08**  **$0.10 $0.07**  **$0.00 $0.25**  1.1 Multiplier used for trimming, + 2 seconds - cast with pin **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9.88 2 4 40 **1.1 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up** 

**Total**

**$1.23 $1.98**  **$4.04 $0.09**  **$0.24 $0.16**  **$0.00 $0.50** 

**$4.54 2** 



### Notes: **a) Items 1,2, & 3 must all equal same**  **value otherwise**  **there is a computation error.** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T** 
**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./**  **Day Hrs./** 
**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**Purchase Part - High Impact Item (Full Cost Mapping)**

H Housing , Actuator, Brake 060602-N0502-27



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**360 10.00**  0.25 H Housing , Actuator, Brake 060602-N0502-27

H Housing , Actuator, Brake 060602-N0502-27A

H Housing , Actuator, Brake 060602-N0502-27B

H Housing , Actuator, Brake 060602-N0502-27C



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 360**  **10.00** 0.25

**38 94.00**  1.00

**585 6.15**  1.50

**364 9.88**  1.00

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-
**#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT


## Technology Level:
**Vehicle Class: Study Case#:**  **System Description: Component Description:** 
**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls
EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

# 606 **02 H Brake Pedal A**  **ssembly Part #**  **QTY $$$**  **Comments**

**H Brake Pedal A**

**ssembly** 1 1.84
H Screw, Brake Pedal Sensor 2 0.14 Commodity pricing H Bolt, Brake Mounting Bracket 2 0.09 Commodity pricing H Bolt, Brake Mounting Bracket 2 0.09 Commodity pricing


# A **H Bracket, Brake to Mounting Bracket** 1 1.66 T2

H W eld Nut, Bracket, Brake 1 0.06

H W eld Nut, Bracket, Brake 1 0.06


# B **H Brake Mounting Bracket A sm.**  1 Not Mapped - Beyond Scope 

# C **H Brake Pedal Subassembly** 1 2.77

H Screw, Brake Actuator 2 0.17 Commodity pricing H Clip, Spring, Brake Pedal Simulator 1 0.005 Commodity pricing? H Spring, Coil, Brake Pedal Return 1 0.08 Commodity pricing H Pivot, Brake Pedal Return Spring 1 0.44 H Latch, Brake Pedal Return Spring 1 0.09
H Pin, Brake, Pivot, Main 1 1.39
H Bracket, Brake Pedal 1 8.21
H Label - Bracket, Brake Pedal 1 0.05
H Pushnut, Fastener 1 0.01 Commodity pricing H Screw - Brake Pedal, Stoplight Switch Brkt 1 0.01 Commodity pricing H Bracket, Brake Pedal Brakelight Switch 1 0.12 

# C1 **H Brake Position Sensor & Brkt A sm**  1 0.21

H Brake Position Sensor Asm 1 5.81 Commodity pricing 

# C1A **H Brake Position Sensor Bracket A sm**  1 0.17

H Brake Position Sensor Bracket 1 0.09

H Brake Position Sensor Brkt Insert 2 0.07 Commodity pricing 

# C2 **H Brake Pedal A ctuator A** 

**sm** 1 4.06 H Housing, Actuator, Brake 1 7.98 Cast - $5.22 H Ball, Plug, Stainless Steel, 3.4 mm 5 0.10 H Coil, Magnetic, Brake Actuator 1 4.65 Commodity pricing H Spring, Coil, Piston, Actuator, Br 1 0.08 Commodity pricing H Spring, Coil, Actuator, Brake 1 1.10 Commodity pricing H Snap Ring - Actuator, Brake 1 0.05 Commodity pricing?
H Nut, Lock, Actuator, Brake 1 0.17 Commodity pricing?
H Clevis, Actuator, Brake 1 1.55 H C-Clip, Brake Actuator Piston 1 0.02 Commodity pricing?
H Label, Brake Pedal Actuator Asm 1 0.12 Commodity pricing
H Fluid, Actuator, Brake 1 0.10 Commodity pricing?

H W ire, Retaining, Plunger, Brake, Actuator 1 0.01 H Sensor, Pressure, Brake Pedal 1 11.55 Commodity pricing 

# C3 **H Piston, A ctuator, Brake**  2 0.30
H Piston, Actuator, W ashed 2 1.60 H O-Ring, Piston, Actuator 2 0.19 Commodity pricing 

# C4 **H Cap, Piston Spring A sm**  1 0.09 H Cap, Rim 1 0.05 H Cap, Button 1 0.04 

# C5 **H Plunger A sm, Brake, A** 

**ctuator** 1 0.11 H Shaft, Actuator, Brake 1 3.42

# H Bell Housing, Actuator, Brake 1 0.91

H Foam W iper, Actuator, Brake 1 0.01 Commodity pricing H Cap, Plunger, Actuator 1 0.03 

# C5A **H Stud and O-Ring A sm, A**  **ctuator** 1 0.61 H Stud, Threaded, Actuator, Brake 1 1.35 H O-Ring, Stud, Actuator, Brake 1 0.07 Commodity pricing H Retainer, Plunger, Actuator, Brake 1 0.72 

# C6 **H Brake Pedal and Simulator A sm**  1 0.13 Push Together 

# C6A **H Brake Pedal A rm Subassembly**  1 0.40

H Bumper, Brake Pedal 1 0.01 Commodity pricing H Bushing, Brake Pedal Pivot 1 0.44 Commodity pricing
H Contact Cover, Brake Pedal 1 1.74 

# C6A1 **H Brake Pedal A rm, Weldment, Painted**  1 0.19

H Brake Pedal Arm, Partial W eldment 1 11.25 H Pin, Brake Pedal Spring Pivot 1 0.66
H Tube, Pivot, Brake Pedal Arm 1 0.12 Commodity pricing H Bar, Brake Pedal Spring 1 1.94 H Bracket, Brake Pedal Stop 1 0.17 H Pedal Contact, Brake Pedal 1 0.25 

# C6B **H Simulator, Brake Pedal A sm**  1 0.89 H Bumper, Leaf Spring, Simulator 1 0.14 H Cover, Simulator, Brake Pedal 1 1.11 H O-Ring, NVH, Simulator Shaft 3 0.02 H Screw, Cover, Brake Pedal Spring, Primary 2 0.11 Commodity pricing 

# C6B1 **H Spring, Leaf, Simulator A sm**  1 0.22 Commodity pricing? H Spring, Leaf, Simulator 1 0.96 Commodity pricing H Pad, Spring, Leaf 1 0.21 H Pad #2, Leaf Spring 1 0.01 

# C6B2 **H Spring, Rubber Bumper Plate asm** 1 0.13

H Spring, Rubber Bumper 1 2.13 Bumper and plate held together w/o adhesive H Plate, Spring, Rubber Bumper 1 0.01 

# C6B3 **H Housing A sm., Simulator, Brake Pedal**  1 0.52 H Housing , Simulator, Brake Pedal 1 5.91 H Pin, Simulator - Actuator 1 0.90 H Pin, Dowel, Split, Simulator Housing 2 0.14 Commodity pricing H Bushing, Brake Simulator Housing 2 0.32 Commodity pricing



# 99 95.71

# Comments

Commodity pricing
Commodity pricing
Commodity pricing 

# galvanized

Not Mapped - Beyond Scope

Commodity pricing
Commodity pricing?
Commodity pricing

Commodity pricing
Commodity pricing

Commodity pricing

Commodity pricing

Cast - $5.22 

# Savings of $2.76

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Commodity pricing?
Commodity pricing?

Commodity pricing?
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Commodity pricing?

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Commodity pricing



# Used LD mat'l cost of $3.00

# Commodity pricing

Commodity pricing 

# Seems expensive

Used LD mat'l cost of $3.00

Push Together

Commodity pricing
Commodity pricing 

# Teflon coating

Commodity pricing

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Commodity pricing

Bumper and plate held together w/o adhesive

Commodity pricing
Commodity pricing

# Assembly Report

**H Brake Pedal A**

**ssembly**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name** 

**Rate** $35.51 Tool H Brake Pedal Assembly First Fixture

- - - Intermediate bracket between mount brkt & pedal $44.96 Subassembly H Brake Pedal Assembly H Bracket, Brake to Mounting Bracket

- - - Spot-Projection W eld Auto Load $44.96 Tool H Bracket, Brake to Mounting Bracket Projection W elder

- - - Stamped bracket $44.96 P.-P. Part H Bracket, Brake to Mounting Bracket H Bracket, Brake to Mounting Bracket - Stamped $44.96 Tool H Bracket, Brake to Mounting Bracket - Stamped Stamping Press 200-400 Ton $44.96 Part H Bracket, Brake to Mounting Bracket - Stamped H Bracket, Brake to Mounting Bracket - Material

- - - Blank weight 1.243 lbs

- - - Press Size 300 Ton & Progressive

- - - Part Size after stamping (190x108x23)mm

- - - We ld nuts (2) $44.96 Part H Bracket, Brake to Mounting Bracket H W eld Nut, Bracket, Brake $44.96 Fastening H Bracket, Brake to Mounting Bracket Projection W eld $44.96 Operation H Bracket, Brake to Mounting Bracket CDI $44.96 Part H Bracket, Brake to Mounting Bracket H W eld Nut, Bracket, Brake $44.96 Fastening H Bracket, Brake to Mounting Bracket Projection W eld

- - - 2 screws $35.51 Tool H Brake Pedal Assembly Power Tool $35.51 Part H Brake Pedal Assembly H Bolt, Brake Mounting Bracket $35.51 Fastening H Brake Pedal Assembly Power Screw $35.51 Operation H Brake Pedal Assembly CDI $35.51 Fastening H Brake Pedal Assembly Power Screw

- - - Brake mounting bracket - same as in gas Fusion $44.96 Subassembly H Brake Pedal Assembly H Brake Mounting Bracket Asm.

- - - 2 screws $35.51 Part H Brake Pedal Assembly H Bolt, Brake Mounting Bracket $35.51 Subassembly H Brake Pedal Assembly H Brake Pedal Subassembly $35.51 Tool H Brake Pedal Subassembly First Fixture $35.51 Subassembly H Brake Pedal Subassembly H Brake Position Sensor & Brkt Asm $35.51 Tool H Brake Position Sensor & Brkt Asm First Fixture $35.51 Subassembly H Brake Position Sensor & Brkt Asm H Brake Position Sensor Asm

- - - Plastic mounting adapter with steel inserts $16.39 Subassembly H Brake Position Sensor & Brkt Asm H Brake Position Sensor Bracket Asm $16.39 Tool H Brake Position Sensor Bracket Asm Press $16.39 P.-P. Part H Brake Position Sensor Bracket Asm H Brake Position Sensor Bracket - Molded

- - - "Injection Molding, Small Size and/or Low Complexi $16.39 Tool H Brake Position Sensor Bracket - Molded Injection Molding Machine 55-150 ton $16.39 Part H Brake Position Sensor Bracket - Molded H Brake Position Sensor Bracket - Material

- - - Raw Material Req 0.033 lbs from Cost Sheet

- - - 6 Cavity Mold

- - - Box Size (60x55x25)mm $44.85 P.-P. Part H Brake Position Sensor Bracket Asm H Brake Position Sensor Brkt Insert $16.39 Fastening H Brake Position Sensor Bracket Asm Press Together $35.51 Subassembly H Brake Pedal Subassembly H Brake Pedal Actuator Asm $35.51 Tool H Brake Pedal Actuator Asm First Fixture

# $49.29 P.-P. Part H Brake Pedal Actuator Asm H Housing, Actuator, Brake

$49.29 Tool H Housing, Actuator, Brake Wa sher Med Batch special nozzels

- - - "W ashing, Medium Size and/or Moderate Complexity" $59.86 P.-P. Part H Housing, Actuator, Brake H Housing, Actuator, Brake - Machined

- - - Machine Block $59.86 Tool H Housing, Actuator, Brake - Machined EC-400-ML Horizontal CNC Machine $28.17 P.-P. Part H Housing, Actuator, Brake - Machined H Housing, Actuator, Brake - Cut Block $28.17 Tool H Housing, Actuator, Brake - Cut Block Cut Off Tool $28.17 Part H Housing, Actuator, Brake - Cut Block H Housing, Actuator, Brake - Extrusion $28.17 Material Mod. H Housing, Actuator, Brake - Cut Block Cut to Length lrg 4-6 inch

- - - Bar stock weight .97 lbs.

- - - Box size of finished part (80x96x35)mm $59.86 Operation H Housing, Actuator, Brake - Machined Load Part $59.86 Operation H Housing, Actuator, Brake - Machined Clamp Part $59.86 Material Mod. H Housing, Actuator, Brake - Machined Milled face $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined CDI $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined CDI $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined CDI $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined CDI $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined CDI $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined Part Manipulation $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Bore Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Cut Groove sml $59.86 Operation H Housing, Actuator, Brake - Machined Part Manipulation $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Gun Drill $59.86 Operation H Housing, Actuator, Brake - Machined Part Manipulation $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Cut Groove sml $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Milled face $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool

# $59.86 Material Mod. H Housing, Actuator, Brake - Machined Cut Groove sml

$59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Drill & Chamfer Hole 1-30mm $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Cut Groove sml $59.86 Operation H Housing, Actuator, Brake - Machined Reposition Cutting Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Cut Groove sml $59.86 Operation H Housing, Actuator, Brake - Machined Part Manipulation $59.86 Material Mod. H Housing, Actuator, Brake - Machined Counter Bore Hole Small $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Gun Drill $59.86 Operation H Housing, Actuator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Clearance Cut $59.86 Operation H Housing, Actuator, Brake - Machined Reposition Cutting Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Clearance Cut $59.86 Operation H Housing, Actuator, Brake - Machined Reposition Cutting Tool $59.86 Material Mod. H Housing, Actuator, Brake - Machined Clearance Cut $59.86 Operation H Housing, Actuator, Brake - Machined Unclamp Part $59.86 Tool H Housing, Actuator, Brake - Machined Label Engraver $59.86 Operation H Housing, Actuator, Brake - Machined Load Part $59.86 Operation H Housing, Actuator, Brake - Machined Clamp Part $59.86 Material Mod. H Housing, Actuator, Brake - Machined Dot Pin Symbolization $59.86 Operation H Housing, Actuator, Brake - Machined Unclamp Part $59.86 Tool H Housing, Actuator, Brake - Machined Special Tool $59.86 Operation H Housing, Actuator, Brake - Machined Part Manipulation $59.86 Operation H Housing, Actuator, Brake - Machined Clamp Part $59.86 Material Mod. H Housing, Actuator, Brake - Machined Stamp Symbolization $59.86 Operation H Housing, Actuator, Brake - Machined Unclamp Part

- - - In-Line W asher

- - - medium batch/individual with special spray nozzels $49.29 Operation H Housing, Actuator, Brake Load Part $49.29 Operation H Housing, Actuator, Brake Wa sh Part Medium $49.29 Operation H Housing, Actuator, Brake Unload Part $35.51 Tool H Brake Pedal Actuator Asm Press $35.51 Part H Brake Pedal Actuator Asm H Ball, Plug, Stainless Steel, 3.4 mm $35.51 Fastening H Brake Pedal Actuator Asm Swedge Together $35.51 Operation H Brake Pedal Actuator Asm CDI $35.51 Operation H Brake Pedal Actuator Asm Part Manipulation $35.51 Operation H Brake Pedal Actuator Asm Part Manipulation $35.51 Operation H Brake Pedal Actuator Asm Part Manipulation $35.51 Subassembly H Brake Pedal Actuator Asm H Coil, Magnetic, Brake Actuator $35.51 Subassembly H Brake Pedal Actuator Asm H Piston, Actuator, Brake $35.51 Tool H Piston, Actuator, Brake Special Tool $35.51 P.-P. Part H Piston, Actuator, Brake H Piston, Actuator, W ashed

- - - "W ashing, Small Size and/or Low Complexity" $35.51 Tool H Piston, Actuator, W ashed Wa sher Duo 400 W ash Rinse & DRY

- - - Batch Type W asher

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $28.18 P.-P. Part H Piston, Actuator, W ashed H Piston, Actuator, Brake, Machined

- - - CNC Turning 1.75" Bar 2 Axis $28.18 Tool H Piston, Actuator, Brake, Machined CNC TL-15 2 Axis Twin Spindle Lathe - Auto Load $28.18 Part H Piston, Actuator, Brake, Machined H Piston, Actuator, Brake - Material

- - - Bar stock weight 0.05 lbs.

# - - - Box size of finished part 23Dmm x 21Lmm

$28.18 Operation H Piston, Actuator, Brake, Machined Load Part $28.18 Operation H Piston, Actuator, Brake, Machined Clamp Part $28.18 Material Mod. H Piston, Actuator, Brake, Machined Turn OD 1-30mm $28.18 Operation H Piston, Actuator, Brake, Machined Reposition Cutting Tool $28.18 Material Mod. H Piston, Actuator, Brake, Machined Turn OD 1-30mm $28.18 Operation H Piston, Actuator, Brake, Machined Reposition Cutting Tool $28.18 Material Mod. H Piston, Actuator, Brake, Machined Turn OD 1-30mm $28.18 Operation H Piston, Actuator, Brake, Machined Reposition Cutting Tool $28.18 Material Mod. H Piston, Actuator, Brake, Machined Turn End face 1-30mm $28.18 Operation H Piston, Actuator, Brake, Machined Reposition Cutting Tool $28.18 Material Mod. H Piston, Actuator, Brake, Machined Turn End face 1-30mm $28.18 Operation H Piston, Actuator, Brake, Machined Reposition Cutting Tool $28.18 Material Mod. H Piston, Actuator, Brake, Machined Cut to Length $28.18 Operation H Piston, Actuator, Brake, Machined Unclamp Part $28.18 Operation H Piston, Actuator, Brake, Machined Part Manipulation

- - - Turn part over to machine other end $28.18 Operation H Piston, Actuator, Brake, Machined Clamp Part $28.18 Material Mod. H Piston, Actuator, Brake, Machined Turn Face Contoured $28.18 Operation H Piston, Actuator, Brake, Machined Unclamp Part $35.51 Operation H Piston, Actuator, W ashed Load Part $35.51 Operation H Piston, Actuator, W ashed Wa sh Part Medium $35.51 Operation H Piston, Actuator, W ashed Unload Part $35.51 P.-P. Part H Piston, Actuator, Brake H O-Ring, Piston, Actuator $35.51 Fastening H Piston, Actuator, Brake Push On

- - - Insert pistons in opposite ends of housing $35.51 P.-P. Part H Brake Pedal Actuator Asm H Spring, Coil, Piston, Actuator, Brake $35.51 Subassembly H Brake Pedal Actuator Asm H Cap, Piston Spring Asm $35.51 Tool H Cap, Piston Spring Asm First Fixture $15.50 P.-P. Part H Cap, Piston Spring Asm H Cap, Rim, Stamped $15.50 Tool H Cap, Rim, Stamped Stamping Press 0-60 Ton $15.50 Part H Cap, Rim, Stamped H Cap, Rim - Material

- - - Blank weight 0.008 lbs

- - - Press Size 25 Ton Progressive

- - - Part Size after stamping (25.7 Dia x 3.8 Deep)mm $35.51 P.-P. Part H Cap, Piston Spring Asm H Cap, Button, Molded $35.51 Fastening H Cap, Piston Spring Asm Snap Together $35.51 Fastening H Brake Pedal Actuator Asm COMPRESS SPRINGS 

# Design Profit ®

Page 1 of 6 Copyright 2005© Munro & Associates, Inc.



# H Brake Pedal A

**ssembly**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name** 

**Rate** $35.51 Tool H Brake Pedal Actuator Asm Hand Tool $35.51 Part H Brake Pedal Actuator Asm H C-Clip, Brake Actuator Piston $35.51 Fastening H Brake Pedal Actuator Asm Push In Place $35.51 Operation H Brake Pedal Actuator Asm Part Manipulation $35.51 Part H Brake Pedal Actuator Asm H Label, Brake Pedal Actuator Asm $35.51 Fastening H Brake Pedal Actuator Asm Push In Place $35.51 Tool H Brake Pedal Actuator Asm Fluid Dispenser $35.51 Part H Brake Pedal Actuator Asm H Fluid, Actuator, Brake $35.51 Operation H Brake Pedal Actuator Asm Fill and Bleed

# $35.51 Subassembly H Brake Pedal Actuator Asm H Plunger Asm, Brake, Actuator

$35.51 Tool H Plunger Asm, Brake, Actuator First Fixture $35.51 P.-P. Part H Plunger Asm, Brake, Actuator H Shaft, Actuator, Brake

- - - "W ashing, Small Size and/or Low Complexity" $35.51 Tool H Shaft, Actuator, Brake Wa sher Duo 400 W ash Rinse & DRY

- - - Batch Type W asher

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $28.18 P.-P. Part H Shaft, Actuator, Brake H Shaft, Actuator, Brake - Machined

- - - CNC TL-15 2 Axis Twin Spindle Lathe - Auto Load $28.18 Tool H Shaft, Actuator, Brake - Machined CNC TL-15 2 Axis Twin Spindle Lathe - Auto Load

- - - Includes Bar Feeder $28.18 Part H Shaft, Actuator, Brake - Machined H Shaft, Actuator, Brake - Material

- - - Bar stock weight 0.35 lbs.

- - - Box size of finished part 21Dmm x 57Lmm $28.18 Operation H Shaft, Actuator, Brake - Machined Load Part $28.18 Operation H Shaft, Actuator, Brake - Machined Clamp Part $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Turn Face Contoured $28.18 Operation H Shaft, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Turn OD Med 60-100mm $28.18 Operation H Shaft, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Turn OD Contoured surface fins $28.18 Operation H Shaft, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Turn OD Med 60-100mm $28.18 Operation H Shaft, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Turn OD Med 60-100mm $28.18 Operation H Shaft, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Turn OD 1-30mm $28.18 Operation H Shaft, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Turn OD 1-30mm $28.18 Material Mod. H Shaft, Actuator, Brake - Machined Cut to Length $28.18 Operation H Shaft, Actuator, Brake - Machined Unclamp Part $35.51 Operation H Shaft, Actuator, Brake Load Part $35.51 Operation H Shaft, Actuator, Brake Wa sh Part Medium $35.51 Operation H Shaft, Actuator, Brake Unload Part $20.81 P.-P. Part H Plunger Asm, Brake, Actuator H Bell Housing, Actuator, Brake

- - - "W ashing, Small Size and/or Low Complexity" $20.81 Tool H Bell Housing, Actuator, Brake Wa sher Duo 400 W ash Rinse & DRY

- - - Batch Type W asher

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $28.18 P.-P. Part H Bell Housing, Actuator, Brake H Bell Housing, Actuator, Brake - Machined

- - - CNC TL-15 2 Axis Twin Spindle Lathe - Auto Load $28.18 Tool H Bell Housing, Actuator, Brake - Machined CNC TL-15 2 Axis Twin Spindle Lathe - Auto Load

- - - Includes Bar Feeder $28.18 Part H Bell Housing, Actuator, Brake - Machined H Bell Housing, Actuator, Brake - Material

- - - Bar stock weight 0.04 lbs.

- - - Box size of finished part 26Dmm x 14Lmm $28.18 Operation H Bell Housing, Actuator, Brake - Machined Load Part $28.18 Operation H Bell Housing, Actuator, Brake - Machined Clamp Part $28.18 Material Mod. H Bell Housing, Actuator, Brake - Machined Bore Hole 1-30mm $28.18 Operation H Bell Housing, Actuator, Brake - Machined Change Tool $28.18 Material Mod. H Bell Housing, Actuator, Brake - Machined Bore Hole 1-30mm $28.18 Operation H Bell Housing, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Bell Housing, Actuator, Brake - Machined Turn OD 1-30mm $28.18 Operation H Bell Housing, Actuator, Brake - Machined Reposition Cutting Tool

# $28.18 Material Mod. H Bell Housing, Actuator, Brake - Machined Turn OD 1-30mm

$28.18 Operation H Bell Housing, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Bell Housing, Actuator, Brake - Machined Cut to Length $28.18 Operation H Bell Housing, Actuator, Brake - Machined Unclamp Part $28.18 Operation H Bell Housing, Actuator, Brake - Machined Part Manipulation $28.18 Operation H Bell Housing, Actuator, Brake - Machined Clamp Part $28.18 Material Mod. H Bell Housing, Actuator, Brake - Machined Turn OD Contoured surface fins $28.18 Operation H Bell Housing, Actuator, Brake - Machined Reposition Cutting Tool $28.18 Material Mod. H Bell Housing, Actuator, Brake - Machined Turn Face Contoured $28.18 Operation H Bell Housing, Actuator, Brake - Machined Unclamp Part

- - - Machine $20.81 Operation H Bell Housing, Actuator, Brake Load Part $20.81 Operation H Bell Housing, Actuator, Brake Wa sh Part Medium $20.81 Operation H Bell Housing, Actuator, Brake Unload Part $35.51 P.-P. Part H Plunger Asm, Brake, Actuator H Foam W iper, Actuator, Brake $15.50 P.-P. Part H Plunger Asm, Brake, Actuator H Cap, Plunger, Actuator $15.50 Tool H Cap, Plunger, Actuator Stamping Press 0-60 Ton $15.50 Part H Cap, Plunger, Actuator H Cap, Plunger, Actuator - Material

- - - Blank weight 0.01 lbs

- - - Press Size 25 Ton Progressive

- - - Part Size after stamping (25.7 Dia x 3.8 Deep)mm

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing $35.51 Subassembly H Plunger Asm, Brake, Actuator H Stud and O-Ring Asm, Actuator $35.51 Tool H Stud and O-Ring Asm, Actuator First Fixture $55.17 P.-P. Part H Stud and O-Ring Asm, Actuator H Stud, Threaded, Actuator, Brake $55.17 Tool H Stud, Threaded, Actuator, Brake Plating Equipment

##### P.-P. Part H Stud, Threaded, Actuator, Brake H Stud, Threaded, Actuator, Brake - Machined

##### Tool H Stud, Threaded, Actuator, Brake - Machined CNC Turning 4 Axis SL-10, 1.75 bar

- - - Includes Bar Feeder

# ##### Part H Stud, Threaded, Actuator, Brake - Machined H Stud, Threaded, Actuator, Brake - Material

- - - Bar stock weight 0.12 lbs.

- - - Box size of finished part 15Dmm x 35Lmm

##### Operation H Stud, Threaded, Actuator, Brake - Machined Load Part

##### Operation H Stud, Threaded, Actuator, Brake - Machined Clamp Part

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Turn OD 30-60mm

##### Operation H Stud, Threaded, Actuator, Brake - Machined Reposition Cutting Tool

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Turn OD 30-60mm

##### Operation H Stud, Threaded, Actuator, Brake - Machined Change Tool

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Milled face

##### Operation H Stud, Threaded, Actuator, Brake - Machined Part Manipulation

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Milled face

##### Operation H Stud, Threaded, Actuator, Brake - Machined Part Manipulation

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Milled face

##### Operation H Stud, Threaded, Actuator, Brake - Machined Part Manipulation

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Milled face

##### Operation H Stud, Threaded, Actuator, Brake - Machined Part Manipulation

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Milled face

##### Operation H Stud, Threaded, Actuator, Brake - Machined Part Manipulation

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Milled face

##### Operation H Stud, Threaded, Actuator, Brake - Machined Change Tool

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Roll Threads

##### Operation H Stud, Threaded, Actuator, Brake - Machined Change Tool

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Cut to Length

##### Material Mod. H Stud, Threaded, Actuator, Brake - Machined Cut to Length

##### Operation H Stud, Threaded, Actuator, Brake - Machined Unclamp Part $55.17 Operation H Stud, Threaded, Actuator, Brake Load Part $55.17 Operation H Stud, Threaded, Actuator, Brake Passivate Part $55.17 Operation H Stud, Threaded, Actuator, Brake Rinse Part $55.17 Operation H Stud, Threaded, Actuator, Brake Remove Part $35.51 Part H Stud and O-Ring Asm, Actuator H O-Ring, Stud, Actuator, Brake $35.51 Fastening H Stud and O-Ring Asm, Actuator Push On $55.17 P.-P. Part H Stud and O-Ring Asm, Actuator H Retainer, Plunger, Actuator, Brake $55.17 Tool H Retainer, Plunger, Actuator, Brake First Fixture $55.17 Tool H Retainer, Plunger, Actuator, Brake Plating Equipment $28.18 P.-P. Part H Retainer, Plunger, Actuator, Brake H Retainer, Plunger, Actuator, Brake - Machined

- - - CNC TL-15 2 Axis Twin Spindle Lathe - Auto Load $28.18 Tool H Retainer, Plunger, Actuator, Brake - Machined CNC TL-15 2 Axis Twin Spindle Lathe - Auto Load

- - - Includes Bar Feeder $28.18 Part H Retainer, Plunger, Actuator, Brake - Machined H Retainer, Plunger, Actuator, Brake - Material

- - - Bar stock weight 0.07 lbs.

- - - Box size of finished part 18Dmm x 15Lmm $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Load Part $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Clamp Part $28.18 Material Mod. H Retainer, Plunger, Actuator, Brake - Machined Bore Hole 1-30mm $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Change Tool $28.18 Material Mod. H Retainer, Plunger, Actuator, Brake - Machined Bore Hole 1-30mm $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Change Tool $28.18 Material Mod. H Retainer, Plunger, Actuator, Brake - Machined Turn OD 1-30mm $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Change Tool $28.18 Material Mod. H Retainer, Plunger, Actuator, Brake - Machined Cut slot $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Unclamp Part $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Part Manipulation $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Clamp Part $28.18 Material Mod. H Retainer, Plunger, Actuator, Brake - Machined Turn OD 1-30mm $28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Change Tool

# $28.18 Material Mod. H Retainer, Plunger, Actuator, Brake - Machined Chamfer OD sml

$28.18 Operation H Retainer, Plunger, Actuator, Brake - Machined Unclamp Part $55.17 Operation H Retainer, Plunger, Actuator, Brake Load Part $55.17 Operation H Retainer, Plunger, Actuator, Brake Passivate Part $55.17 Operation H Retainer, Plunger, Actuator, Brake Rinse Part $55.17 Operation H Retainer, Plunger, Actuator, Brake Remove Part $35.51 Tool H Stud and O-Ring Asm, Actuator Special Tool $35.51 Material Mod. H Stud and O-Ring Asm, Actuator Swage $35.51 Tool H Brake Pedal Actuator Asm Special Tool $35.51 Part H Brake Pedal Actuator Asm H W ire, Retaining, Plunger, Brake, Actuator $35.51 Fastening H Brake Pedal Actuator Asm Insert Retainer $35.51 Material Mod. H Brake Pedal Actuator Asm Cut to Length $35.51 Tool H Brake Pedal Actuator Asm Glue Bottle $35.51 Fastening H Brake Pedal Actuator Asm Apply Glue $35.51 P.-P. Part H Brake Pedal Actuator Asm H Spring, Coil, Actuator, Brake $35.51 Fastening H Brake Pedal Actuator Asm COMPRESS SPRINGS $35.51 Tool H Brake Pedal Actuator Asm Hand Tool $35.51 Part H Brake Pedal Actuator Asm H Snap Ring - Actuator, Brake $35.51 Fastening H Brake Pedal Actuator Asm Push In Place $35.51 Tool H Brake Pedal Actuator Asm Power Tool $35.51 Part H Brake Pedal Actuator Asm H Nut, Lock, Actuator, Brake $35.51 Fastening H Brake Pedal Actuator Asm Power Screw

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# Design Profit ®

Page 2 of 6 Copyright 2005© Munro & Associates, Inc.



# H Brake Pedal A

**ssembly**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name** 

**Rate**

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- - - Space for Printing $10.75 P.-P. Part H Brake Pedal Actuator Asm H Clevis, Actuator, Brake

- - - "W ashing, Small Size and/or Low Complexity" $10.75 Tool H Clevis, Actuator, Brake Wa sher Duo 400 W ash Rinse & DRY

# - - - Batch Type W asher

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $41.20 P.-P. Part H Clevis, Actuator, Brake H Clevis, Actuator, Brake, Machined $41.20 Tool H Clevis, Actuator, Brake, Machined First Fixture $28.18 P.-P. Part H Clevis, Actuator, Brake, Machined H Clevis, Actuator, Brake - Turned $28.18 Tool H Clevis, Actuator, Brake - Turned CNC Turning 2 Axis SL-10, 1.75" bar

- - - CNC Turning 1.75" Bar 2 Axis

- - - Includes Bar Feeder $28.18 Part H Clevis, Actuator, Brake - Turned H Clevis, Actuator, Brake, Material

- - - Bar stock weight 0.24 lbs.

- - - Box size of finished part (35x22x11)mm $28.18 Operation H Clevis, Actuator, Brake - Turned Load Part $28.18 Operation H Clevis, Actuator, Brake - Turned Clamp Part $28.18 Material Mod. H Clevis, Actuator, Brake - Turned Turn OD 1-30mm $28.18 Operation H Clevis, Actuator, Brake - Turned CDI $28.18 Material Mod. H Clevis, Actuator, Brake - Turned Turn OD 1-30mm $28.18 Operation H Clevis, Actuator, Brake - Turned CDI $28.18 Material Mod. H Clevis, Actuator, Brake - Turned Turn End face 1-30mm $28.18 Operation H Clevis, Actuator, Brake - Turned CDI $28.18 Material Mod. H Clevis, Actuator, Brake - Turned Turn End face 1-30mm $28.18 Operation H Clevis, Actuator, Brake - Turned CDI $28.18 Material Mod. H Clevis, Actuator, Brake - Turned Turn End Face 30-60mm $28.18 Material Mod. H Clevis, Actuator, Brake - Turned Cut to Length $28.18 Operation H Clevis, Actuator, Brake - Turned Unclamp Part $41.20 Operation H Clevis, Actuator, Brake, Machined Load Part $41.20 Operation H Clevis, Actuator, Brake, Machined Clamp Part $41.20 Material Mod. H Clevis, Actuator, Brake, Machined Drill & Chamfer Hole 1-30mm $41.20 Operation H Clevis, Actuator, Brake, Machined Part Manipulation $41.20 Material Mod. H Clevis, Actuator, Brake, Machined Drill & Chamfer Hole 1-30mm $41.20 Operation H Clevis, Actuator, Brake, Machined Part Manipulation $41.20 Material Mod. H Clevis, Actuator, Brake, Machined Drill and Tap Hole 1-30mm $41.20 Operation H Clevis, Actuator, Brake, Machined Unclamp Part $41.20 Material Mod. H Clevis, Actuator, Brake, Machined Debur/Tumble $10.75 Operation H Clevis, Actuator, Brake Load Part $10.75 Operation H Clevis, Actuator, Brake Wa sh Part Medium $10.75 Operation H Clevis, Actuator, Brake Unload Part $35.51 Fastening H Brake Pedal Actuator Asm Power Screw $35.51 Tool H Brake Pedal Actuator Asm Power Tool $35.51 Subassembly H Brake Pedal Actuator Asm H Sensor, Pressure, Brake Pedal $35.51 Fastening H Brake Pedal Actuator Asm Power Screw $35.51 Part H Brake Pedal Subassembly H Screw, Brake Actuator $35.51 Tool H Brake Pedal Subassembly Power Tool $35.51 Fastening H Brake Pedal Subassembly Power Screw $35.51 Part H Brake Pedal Subassembly H Clip, Spring, Brake Pedal Simulator $35.51 Tool H Brake Pedal Subassembly Hand Tool $35.51 Fastening H Brake Pedal Subassembly Install Spring Clip $35.51 Part H Brake Pedal Subassembly H Spring, Coil, Brake Pedal Return

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- - - Space for Printing $16.39 P.-P. Part H Brake Pedal Subassembly H Pivot, Brake Pedal Return Spring - Molded

- - - "Injection Molding, Small Size and/or Low Complexi $16.39 Tool H Pivot, Brake Pedal Return Spring - Molded Injection Molding Machine 55-150 ton $16.39 Part H Pivot, Brake Pedal Return Spring - Molded H Pivot, Brake Pedal Return Spring - Material

- - - High cycle time is due to thick solid post

- - - Raw Material Req 0.028 lbs from Cost Sheet

- - - 9 Cavity Mold

- - - Box Size (51x27x27)mm $16.39 P.-P. Part H Brake Pedal Subassembly H Latch, Brake Pedal Return Spring - Molded

- - - "Injection Molding, Small Size and/or Low Complexi $16.39 Tool H Latch, Brake Pedal Return Spring - Molded Injection Molding Machine 55-150 ton $16.39 Part H Latch, Brake Pedal Return Spring - Molded H Latch, Brake Pedal Return Spring - Material

- - - Raw Material Req 0.031 lbs from Cost Sheet

- - - 9 Cavity Mold

- - - Box Size (53x26x26)mm $35.51 Fastening H Brake Pedal Subassembly Gross Deform

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- - - Space for Printing $10.75 P.-P. Part H Brake Pedal Subassembly H Pin, Brake, Pivot, Main

- - - "W ashing, Small Size and/or Low Complexity" $10.75 Tool H Pin, Brake, Pivot, Main Wa sher Duo 400 W ash Rinse & DRY $37.60 P.-P. Part H Pin, Brake, Pivot, Main H Pin, Brake, Pivot, Machined

- - - CNC Turning 1.75" Bar 2 Axis $37.60 Tool H Pin, Brake, Pivot, Machined CNC Turning 2 Axis SL-10, 1.75" bar

- - - Includes Bar Feeder $37.60 Part H Pin, Brake, Pivot, Machined H Pin, Brake, Pivot, Material

- - - In symbol put material and piece cost

- - - Bar stock weight 0.42 lbs.

- - - Box size of finished part 17mm x 106mm

- - - Add machining steps (Mateial Mods) $37.60 Material Mod. H Pin, Brake, Pivot, Machined Turn OD 1-30mm $37.60 Operation H Pin, Brake, Pivot, Machined Reposition Cutting Tool $37.60 Material Mod. H Pin, Brake, Pivot, Machined Turn OD 1-30mm $37.60 Operation H Pin, Brake, Pivot, Machined Reposition Cutting Tool $37.60 Material Mod. H Pin, Brake, Pivot, Machined Chamfer OD sml $37.60 Operation H Pin, Brake, Pivot, Machined Reposition Cutting Tool $37.60 Material Mod. H Pin, Brake, Pivot, Machined Chamfer OD sml $37.60 Operation H Pin, Brake, Pivot, Machined Change Tool $37.60 Material Mod. H Pin, Brake, Pivot, Machined Knurl OD $37.60 Operation H Pin, Brake, Pivot, Machined Reposition Cutting Tool $37.60 Material Mod. H Pin, Brake, Pivot, Machined Knurl OD $37.60 Operation H Pin, Brake, Pivot, Machined Reposition Cutting Tool

# $37.60 Material Mod. H Pin, Brake, Pivot, Machined Cut to Length

- - - Zinc Phosphate Coating process here $37.60 Tool H Pin, Brake, Pivot, Machined Anodizing Equipment

- - - Zinc Phosphate Coating - Batch Processed $37.60 Operation H Pin, Brake, Pivot, Machined Load Part

- - - Surface area = 8.4 square inches $37.60 Operation H Pin, Brake, Pivot, Machined Electroplate Process $37.60 Operation H Pin, Brake, Pivot, Machined Remove Part

- - - Batch Type W asher

- - - 5-10 min cycle time 

# Design Profit ®

Page 3 of 6 Copyright 2005© Munro & Associates, Inc.



# H Brake Pedal A

**ssembly**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name** 

**Rate**

- - - Basket Size 15.75x18.50x25.50 inches x 2 $10.75 Operation H Pin, Brake, Pivot, Main Load Part $10.75 Operation H Pin, Brake, Pivot, Main Wa sh Part Medium $10.75 Operation H Pin, Brake, Pivot, Main Unload Part $49.29 P.-P. Part H Brake Pedal Subassembly H Bracket, Brake Pedal

- - - "W ashing, Medium Size and/or Moderate Complexity" $49.29 Tool H Bracket, Brake Pedal Wa sher Med Batch special nozzels

- - - In-Line W asher

- - - medium batch/individual with special spray nozzels $31.33 P.-P. Part H Bracket, Brake Pedal H Bracket, Brake Pedal Machined $31.33 Tool H Bracket, Brake Pedal Machined EC-300-ML Horizontal CNC Machine

- - - Part Symbol $31.33 P.-P. Part H Bracket, Brake Pedal Machined H Bracket, Brake Pedal Casting - Trimmed $31.33 Tool H Bracket, Brake Pedal Casting - Trimmed Trim Press

##### P.-P. Part H Bracket, Brake Pedal Casting - Trimmed H Bracket, Brake Pedal Casting

- - - "Aluminum Diecasting, Medium Size and/or Moderate

##### Tool H Bracket, Brake Pedal Casting Die Casting 1000-1800 ton

- - - Add Part Symbol

##### Part H Bracket, Brake Pedal Casting H Bracket, Brake Pedal Casting - Material

- - - Raw Material Req 2.032 lbs from Cost Sheet

- - - 4 Cavity Mold

- - - Box Size (217x178x127)mm $31.33 Operation H Bracket, Brake Pedal Machined Load Part $31.33 Operation H Bracket, Brake Pedal Machined Clamp Part $31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face

# $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation

$31.33 Material Mod. H Bracket, Brake Pedal Machined Milled face $31.33 Operation H Bracket, Brake Pedal Machined Change Tool $31.33 Material Mod. H Bracket, Brake Pedal Machined Cut slot $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Cut slot $31.33 Operation H Bracket, Brake Pedal Machined Change Tool

- - - Drill and tap 4.6 mm holes (3 places) $31.33 Material Mod. H Bracket, Brake Pedal Machined Drill and Tap Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined CDI $31.33 Material Mod. H Bracket, Brake Pedal Machined Drill and Tap Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined Part Manipulation $31.33 Material Mod. H Bracket, Brake Pedal Machined Drill and Tap Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined Change Tool

- - - Drill and tap 3.2 mm holes (2 places) $31.33 Material Mod. H Bracket, Brake Pedal Machined Drill and Tap Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined CDI $31.33 Material Mod. H Bracket, Brake Pedal Machined Drill and Tap Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined Change Tool

- - - Bore 8 mm hole $31.33 Material Mod. H Bracket, Brake Pedal Machined Bore Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined Change Tool

- - - Bore 16.2 mm hole $31.33 Material Mod. H Bracket, Brake Pedal Machined Drill Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined Change Tool

- - - Bore 11 mm hole $31.33 Material Mod. H Bracket, Brake Pedal Machined Drill Hole 1-30mm $31.33 Operation H Bracket, Brake Pedal Machined Change Tool $31.33 Operation H Bracket, Brake Pedal Machined Unclamp Part $49.29 Operation H Bracket, Brake Pedal Load Part $49.29 Operation H Bracket, Brake Pedal Wa sh Part Medium $49.29 Operation H Bracket, Brake Pedal Unload Part $35.51 Tool H Brake Pedal Subassembly Press $35.51 Fastening H Brake Pedal Subassembly Press Together $35.51 Operation H Brake Pedal Subassembly Part Manipulation $35.51 Part H Brake Pedal Subassembly H Pushnut, Fastener - Brake Pedal Pivot $35.51 Fastening H Brake Pedal Subassembly Press Together $35.51 Tool H Brake Pedal Subassembly Power Tool

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- - - Space for Printing $35.51 Part H Brake Pedal Subassembly H Screw - Brake Pedal, Stoplight Switch Brkt $42.91 P.-P. Part H Brake Pedal Subassembly H Bracket, Brake Pedal Brakelight Switch $42.91 Tool H Bracket, Brake Pedal Brakelight Switch Stamping Press 200-400 Ton $42.91 Part H Bracket, Brake Pedal Brakelight Switch H Bracket, Brake Pedal Brakelight Switch Material

- - - Blank weight 0.12 lbs

- - - Press Size200 Ton Progressive

- - - Part Size after stamping (99x32x20)mm $35.51 Fastening H Brake Pedal Subassembly Power Screw

- - - Space for Printing

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- - - Space for Printing $35.51 Subassembly H Brake Pedal Subassembly H Brake Pedal and Simulator Asm $35.51 Tool H Brake Pedal and Simulator Asm First Fixture $35.51 Subassembly H Brake Pedal and Simulator Asm H Brake Pedal Arm Subassembly $35.51 Tool H Brake Pedal Arm Subassembly First Fixture

- - - Attach bushing, bumper, and contact cover $55.17 Subassembly H Brake Pedal Arm Subassembly H Brake Pedal Arm, W eldment, Painted $55.17 Tool H Brake Pedal Arm, W eldment, Painted Paint Line

- - - Paint line - dipped in liquid paint - air dried $55.17 Operation H Brake Pedal Arm, W eldment, Painted Load Part $20.81 Subassembly H Brake Pedal Arm, W eldment, Painted H Brake Pedal Arm, W eldment, W ashed $20.81 Tool H Brake Pedal Arm, W eldment, W ashed Wa sher Turbo Tunnel

- - - In-Line W asher $44.96 Subassembly H Brake Pedal Arm, W eldment, W ashed H Brake Pedal Arm, W eldment, Machined $44.96 Tool H Brake Pedal Arm, W eldment, Machined Projection W elder

- - - Final W elding $44.96 Operation H Brake Pedal Arm, W eldment, Machined Clamp Part

##### Subassembly H Brake Pedal Arm, W eldment, Machined H Brake Pedal, Partial W eldment, Machined

##### Tool H Brake Pedal, Partial W eldment, Machined EC-400-ML Horizontal CNC Machine $44.96 Subassembly H Brake Pedal, Partial W eldment, Machined H Brake Pedal Arm Partial W eldment

# $44.96 Tool H Brake Pedal Arm Partial W eldment Projection W elder

- - - Initial W elding $42.18 Subassembly H Brake Pedal Arm Partial W eldment H Brake Pedal Arm, Swaged $42.18 Tool H Brake Pedal Arm, Swaged Press

- - - Pressing and Swaging $35.42 Subassembly H Brake Pedal Arm, Swaged H Brake Pedal Arm Partial W eldment (stage 1) $35.42 Tool H Brake Pedal Arm Partial W eldment (stage 1) EC-400-ML Horizontal CNC Machine

- - - Initial machining - holes in pedal arm $42.91 P.-P. Part H Brake Pedal Arm Partial W eldment (stage 1) H Brake Pedal Arm Stamping $42.91 Tool H Brake Pedal Arm Stamping Stamping Press 200-400 Ton

- - - Stamping the brake pedal arm $42.91 Part H Brake Pedal Arm Stamping H Brake Pedal Arm Material

- - - Blank weight 10.62 lbs

- - - Press Size 300 Ton, Prog. Die

- - - Part Size after stamping (356x155x112)mm $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) Load Part $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) Clamp Part $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Bore Hole 1-30mm $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) CDI $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Bore Hole 1-30mm $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) CDI $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Bore Hole 1-30mm $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) CDI $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Bore Hole 1-30mm $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) Change Tool $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Cut slot $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) CDI $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Cut slot $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) Change Tool $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Chamfer Edge $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) CDI $35.42 Material Mod. H Brake Pedal Arm Partial W eldment (stage 1) Chamfer Edge $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) Unclamp Part $35.42 Operation H Brake Pedal Arm Partial W eldment (stage 1) Part Manipulation $10.75 P.-P. Part H Brake Pedal Arm, Swaged H Pin, Brake Pedal Spring Pivot $10.75 Tool H Pin, Brake Pedal Spring Pivot Wa sher Duo 400 W ash Rinse & DRY $20.90 P.-P. Part H Pin, Brake Pedal Spring Pivot H Pin, Brake Pedal Spring Pivot - Machined $20.90 Tool H Pin, Brake Pedal Spring Pivot - Machined CNC Turning 2 Axis SL-10, 1.75" bar

- - - Includes Bar Feeder $20.90 Part H Pin, Brake Pedal Spring Pivot - Machined H Pin, Brake Pedal Spring Pivot - Material

- - - Bar stock weight 0.14 lbs.

- - - Box size of finished part 14Dmm x 45Lmm $20.90 Material Mod. H Pin, Brake Pedal Spring Pivot - Machined Turn OD 1-30mm $20.90 Operation H Pin, Brake Pedal Spring Pivot - Machined CDI $20.90 Material Mod. H Pin, Brake Pedal Spring Pivot - Machined Turn OD 1-30mm $20.90 Operation H Pin, Brake Pedal Spring Pivot - Machined CDI $20.90 Material Mod. H Pin, Brake Pedal Spring Pivot - Machined Turn OD 1-30mm $20.90 Operation H Pin, Brake Pedal Spring Pivot - Machined CDI $20.90 Material Mod. H Pin, Brake Pedal Spring Pivot - Machined Turn OD 1-30mm $20.90 Material Mod. H Pin, Brake Pedal Spring Pivot - Machined Cut to Length

- - - Batch Type W asher

- - - 5-10 min cycle time 

# Design Profit ®

Page 4 of 6 Copyright 2005© Munro & Associates, Inc.

# H Brake Pedal A **ssembly**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name** 

**Rate**

- - - Basket Size 15.75x18.50x25.50 inches x 2 $10.75 Operation H Pin, Brake Pedal Spring Pivot Load Part $10.75 Operation H Pin, Brake Pedal Spring Pivot Wa sh Part Medium $10.75 Operation H Pin, Brake Pedal Spring Pivot Unload Part $42.18 Tool H Brake Pedal Arm, Swaged Swage Tool $42.18 Material Mod. H Brake Pedal Arm, Swaged Swage $35.51 P.-P. Part H Brake Pedal Arm, Swaged H Tube, Pivot, Brake Pedal Arm $42.18 Material Mod. H Brake Pedal Arm, Swaged Swage $42.18 Operation H Brake Pedal Arm, Swaged Part Manipulation $42.18 Material Mod. H Brake Pedal Arm, Swaged Swage $44.96 Operation H Brake Pedal Arm Partial W eldment Clamp Part

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- - - Space for Printing $35.51 P.-P. Part H Brake Pedal Arm Partial W eldment H Bar, Brake Pedal Spring $35.51 Tool H Bar, Brake Pedal Spring Wa sher Duo 400 W ash Rinse & DRY

- - - Wa sh $35.51 P.-P. Part H Bar, Brake Pedal Spring H Bar, Brake Pedal Spring - machined $35.51 Tool H Bar, Brake Pedal Spring - machined EC-300-ML Horizontal CNC Machine

- - - Spot face flush end of bar $35.51 Operation H Bar, Brake Pedal Spring - machined Load Part $35.51 Operation H Bar, Brake Pedal Spring - machined Clamp Part $35.51 P.-P. Part H Bar, Brake Pedal Spring - machined H Bar, Brake Pedal Spring - cut $35.51 Tool H Bar, Brake Pedal Spring - cut Cut Off Tool

- - - Forge bar stock to shape $35.51 Part H Bar, Brake Pedal Spring - cut H Bar, Brake Pedal Spring - bar stock $35.51 Material Mod. H Bar, Brake Pedal Spring - cut Cut to Length $35.51 Tool H Bar, Brake Pedal Spring - cut Grinder $35.51 Material Mod. H Bar, Brake Pedal Spring - cut Grind Flat $35.51 Material Mod. H Bar, Brake Pedal Spring - machined Spot Face Small 1-30mm $35.51 Operation H Bar, Brake Pedal Spring - machined Unclamp Part

- - - Batch Type W asher

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $35.51 Operation H Bar, Brake Pedal Spring Load Part $35.51 Operation H Bar, Brake Pedal Spring Wa sh Part Medium $35.51 Operation H Bar, Brake Pedal Spring Unload Part $44.96 Fastening H Brake Pedal Arm Partial W eldment Seam W eld $44.96 Operation H Brake Pedal Arm Partial W eldment CDI $44.96 Fastening H Brake Pedal Arm Partial W eldment Seam W eld $44.96 Operation H Brake Pedal Arm Partial W eldment Unclamp Part

- - - Final machining

##### Operation H Brake Pedal, Partial W eldment, Machined Load Part

##### Operation H Brake Pedal, Partial W eldment, Machined Clamp Part

# - - - Cut pivot to length

##### Material Mod. H Brake Pedal, Partial W eldment, Machined Cut to Length

##### Operation H Brake Pedal, Partial W eldment, Machined Change Tool

##### Material Mod. H Brake Pedal, Partial W eldment, Machined Chamfer ID

##### Operation H Brake Pedal, Partial W eldment, Machined Part Manipulation

##### Material Mod. H Brake Pedal, Partial W eldment, Machined Chamfer OD sml

##### Operation H Brake Pedal, Partial W eldment, Machined Change Tool

##### Material Mod. H Brake Pedal, Partial W eldment, Machined Milled face

##### Operation H Brake Pedal, Partial W eldment, Machined CDI

##### Material Mod. H Brake Pedal, Partial W eldment, Machined Milled face

##### Operation H Brake Pedal, Partial W eldment, Machined CDI

##### Material Mod. H Brake Pedal, Partial W eldment, Machined Milled face

##### Operation H Brake Pedal, Partial W eldment, Machined CDI

##### Material Mod. H Brake Pedal, Partial W eldment, Machined Milled face

##### Operation H Brake Pedal, Partial W eldment, Machined Unclamp Part $44.96 Operation H Brake Pedal Arm, W eldment, Machined Clamp Part $44.96 P.-P. Part H Brake Pedal Arm, W eldment, Machined H Bracket, Brake Pedal Stop $44.96 Tool H Bracket, Brake Pedal Stop Stamping Press 0-60 Ton

- - - Add part symbol for raw material (sheet stock) $44.96 Part H Bracket, Brake Pedal Stop H Bracket, Brake Pedal Stop - Material

- - - Blank weight 0.229 lbs

- - - Press Size 60 ton progressive

- - - Part Size after stamping (50x48x32)mm $44.96 Fastening H Brake Pedal Arm, W eldment, Machined Seam W eld $44.96 Operation H Brake Pedal Arm, W eldment, Machined CDI $44.96 Fastening H Brake Pedal Arm, W eldment, Machined Seam W eld $44.96 Operation H Brake Pedal Arm, W eldment, Machined Clamp Part $15.50 P.-P. Part H Brake Pedal Arm, W eldment, Machined H Pedal Contact, Brake Pedal $15.50 Tool H Pedal Contact, Brake Pedal Stamping Press 0-60 Ton $15.50 Part H Pedal Contact, Brake Pedal H Pedal Contact, Brake Pedal, Raw Material

- - - Blank weight 0.398 lbs

- - - Press Size 25 Ton, Prog. Die

- - - Part Size after stamping (113 L by 58 W by 9 H)mm $44.96 Fastening H Brake Pedal Arm, W eldment, Machined Seam W eld $44.96 Operation H Brake Pedal Arm, W eldment, Machined CDI $44.96 Fastening H Brake Pedal Arm, W eldment, Machined Seam W eld $44.96 Operation H Brake Pedal Arm, W eldment, Machined Unclamp Part $20.81 Operation H Brake Pedal Arm, W eldment, W ashed Load Part $20.81 Operation H Brake Pedal Arm, W eldment, W ashed Wa sh Part Medium $20.81 Operation H Brake Pedal Arm, W eldment, W ashed Unload Part $55.17 Operation H Brake Pedal Arm, W eldment, Painted Unload Part $35.51 Part H Brake Pedal Arm Subassembly H Bumper, Brake Pedal $35.51 Fastening H Brake Pedal Arm Subassembly Push In Place $42.18 P.-P. Part H Brake Pedal Arm Subassembly H Bushing, Brake Pedal Pivot $35.51 Fastening H Brake Pedal Arm Subassembly Push In Place

- - - Space for Printing

- - - Space for Printing $28.80 P.-P. Part H Brake Pedal Arm Subassembly H Contact Cover, Brake Pedal $28.80 Tool H Contact Cover, Brake Pedal Injection Molding Machine 200-400 Ton $28.80 Part H Contact Cover, Brake Pedal H Contact Cover, Brake Pedal, Raw Material

- - - Raw Material Req 0.178 lbs from Cost Sheet

- - - 4 Cavity Mold

- - - Box Size 125mm L x 75mm W x 17mm H $35.51 Fastening H Brake Pedal Arm Subassembly Fixture Cover to Base

- - - Space for Printing

- - - Space for Printing

# - - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing $35.51 Subassembly H Brake Pedal and Simulator Asm H Simulator, Brake Pedal Asm $35.51 Tool H Simulator, Brake Pedal Asm First Fixture $35.51 Subassembly H Simulator, Brake Pedal Asm H Housing, Simlator, Brake Pedal $35.51 Tool H Housing, Simlator, Brake Pedal Press

- - - Wa shed machined housing $20.81 Subassembly H Housing, Simlator, Brake Pedal H Housing Asm, Brake, Simulator

- - - "W ashing, Small Size and/or Low Complexity" $20.81 Tool H Housing Asm, Brake, Simulator Wa sher Duo 400 W ash Rinse & DRY

- - - Batch Type W asher

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $59.86 Subassembly H Housing Asm, Brake, Simulator H Housing, Simulator, Brake - Machined

- - - "CNC Horz Mach, Man Med Size and/or Moderate Comp $59.86 Tool H Housing, Simulator, Brake - Machined EC-550-ML Horizontal CNC Machine

##### Subassembly H Housing, Simulator, Brake - Machined H Housing, Simulator, Brake - Casting

##### Tool H Housing, Simulator, Brake - Casting Die Casting 1000-1800 ton

- - - "Aluminum Diecasting, Medium Size and/or Moderate $55.17 P.-P. Part H Housing, Simulator, Brake - Casting H Pin, Simulator - Actuator $55.17 Tool H Pin, Simulator - Actuator Plating Equipment

- - - Zinc Plating, Batched Processed $10.75 P.-P. Part H Pin, Simulator - Actuator H Pin, Simulator - Actuator - W ashed

- - - "W ashing, Small Size and/or Low Complexity" $10.75 Tool H Pin, Simulator - Actuator - W ashed Wa sher Duo 400 W ash Rinse & DRY

- - - Batch Type W asher

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $20.90 P.-P. Part H Pin, Simulator - Actuator - W ashed H Pin, Simulator - Actuator - Machined

- - - CNC Turning 1.75" Bar 2 Axis $20.90 Tool H Pin, Simulator - Actuator - Machined CNC Turning 2 Axis SL-10, 1.75" bar

- - - Includes Bar Feeder $20.90 Part H Pin, Simulator - Actuator - Machined H PIn, Simulator - Actuator - Material

- - - Bar stock weight 0.07 lbs.

- - - Box size of finished part 20mm x 31mm

- - - Add machining steps (Mateial Mods) $20.90 Material Mod. H Pin, Simulator - Actuator - Machined Turn OD 1-30mm $20.90 Operation H Pin, Simulator - Actuator - Machined CDI

# $20.90 Material Mod. H Pin, Simulator - Actuator - Machined Turn OD 1-30mm

$20.90 Operation H Pin, Simulator - Actuator - Machined CDI $20.90 Material Mod. H Pin, Simulator - Actuator - Machined Turn OD 1-30mm $20.90 Operation H Pin, Simulator - Actuator - Machined CDI $20.90 Material Mod. H Pin, Simulator - Actuator - Machined Turn OD 1-30mm $20.90 Operation H Pin, Simulator - Actuator - Machined CDI $20.90 Material Mod. H Pin, Simulator - Actuator - Machined Turn OD 1-30mm $20.90 Operation H Pin, Simulator - Actuator - Machined CDI $20.90 Material Mod. H Pin, Simulator - Actuator - Machined Chamfer OD sml $20.90 Operation H Pin, Simulator - Actuator - Machined CDI $20.90 Material Mod. H Pin, Simulator - Actuator - Machined Cut to Length $10.75 Operation H Pin, Simulator - Actuator - W ashed Load Part $10.75 Operation H Pin, Simulator - Actuator - W ashed Wa sh Part Medium $10.75 Operation H Pin, Simulator - Actuator - W ashed Unload Part $55.17 Operation H Pin, Simulator - Actuator Load Part

- - - Input Surface area as Square Inches

- - - Example: 1" x 1" x 1" Cube = 6" $55.17 Operation H Pin, Simulator - Actuator Electroplate Process $55.17 Operation H Pin, Simulator - Actuator Remove Part

- - - Cast in place pin

##### Part H Housing, Simulator, Brake - Casting H Housing, Simulator, Brake - Material

- - - Raw Material Req 0.956 lbs from Cost Sheet

- - - 4 Cavity Mold

- - - Box Size 120x100x73mm $59.86 Operation H Housing, Simulator, Brake - Machined Load Part $59.86 Operation H Housing, Simulator, Brake - Machined Clamp Part $59.86 Material Mod. H Housing, Simulator, Brake - Machined Mill Small Face $59.86 Operation H Housing, Simulator, Brake - Machined Reposition Cutting Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Mill Small Face $59.86 Operation H Housing, Simulator, Brake - Machined Reposition Cutting Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Mill Small Face $59.86 Operation H Housing, Simulator, Brake - Machined Reposition Cutting Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Mill Small Face $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Drill and Tap Hole 1-30mm $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Drill and Tap Hole 1-30mm $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool 

# Design Profit ®

Page 5 of 6 Copyright 2005© Munro & Associates, Inc.



# H Brake Pedal A

**ssembly**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name** 

**Rate** $59.86 Material Mod. H Housing, Simulator, Brake - Machined Bore Hole 1-30mm $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Bore Hole 1-30mm $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Bore Hole 1-30mm $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Bore Hole 1-30mm $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Bore Hole 1-30mm

# $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool

$59.86 Material Mod. H Housing, Simulator, Brake - Machined Mill Face $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Mill Face $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer ID $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer ID $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer ID $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer ID $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer ID $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer OD sml $59.86 Operation H Housing, Simulator, Brake - Machined Part Manipulation $59.86 Material Mod. H Housing, Simulator, Brake - Machined Mill Face $59.86 Operation H Housing, Simulator, Brake - Machined Change Tool $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer ID $59.86 Operation H Housing, Simulator, Brake - Machined CDI $59.86 Material Mod. H Housing, Simulator, Brake - Machined Chamfer OD sml $59.86 Operation H Housing, Simulator, Brake - Machined Unclamp Part $20.81 Operation H Housing Asm, Brake, Simulator Load Part $20.81 Operation H Housing Asm, Brake, Simulator Wa sh Part Medium $20.81 Operation H Housing Asm, Brake, Simulator Unload Part $35.51 Part H Housing, Simlator, Brake Pedal H Pin, Dowel, Split, Simulator Housing $35.51 Operation H Housing, Simlator, Brake Pedal CDI $35.51 Fastening H Housing, Simlator, Brake Pedal Press Together $35.51 P.-P. Part H Housing, Simlator, Brake Pedal H Bushing, Brake Simulator Housing $35.51 Operation H Housing, Simlator, Brake Pedal Compress part $35.51 Fastening H Housing, Simlator, Brake Pedal Push In Place $35.51 Operation H Housing, Simlator, Brake Pedal Part Manipulation $35.51 Operation H Housing, Simlator, Brake Pedal Compress part $35.51 Fastening H Housing, Simlator, Brake Pedal Push In Place $35.51 Tool H Housing, Simlator, Brake Pedal Label Engraver $35.51 Material Mod. H Housing, Simlator, Brake Pedal Dot Pin Symbolization $16.39 P.-P. Part H Simulator, Brake Pedal Asm H Bumper, Leaf Spring, Simulator

- - - "Injection Molding, Small Size and/or Low Complexi $16.39 Tool H Bumper, Leaf Spring, Simulator Injection Molding Machine 55-150 ton $16.39 Part H Bumper, Leaf Spring, Simulator H Bumper, Leaf Spring, Simulator - Material

- - - Raw Material Req 0.006 lbs from Cost Sheet

- - - 16 Cavity Mold

- - - Box Size 29mm L x 11mm W x 9mm H

- - - Leaf spring asm

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

# - - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing $35.51 Subassembly H Simulator, Brake Pedal Asm H Spring, Leaf, Simulator Asm $35.51 Tool H Spring, Leaf, Simulator Asm First Fixture $35.51 P.-P. Part H Spring, Leaf, Simulator Asm H Spring, Leaf, Simulator $35.51 P.-P. Part H Spring, Leaf, Simulator Asm H Pad #2, Leaf Spring

- - - "Injection Molding, Small Size and/or Low Complexi $35.51 Tool H Pad #2, Leaf Spring Injection Molding Machine 55-150 ton $35.51 Part H Pad #2, Leaf Spring H Pad #2, Leaf Spring - Material

- - - Raw Material Req 0.002 lbs from Cost Sheet

- - - 8 Cavity Mold

- - - Box Size 24mm L x 22mm W x 4mm H $35.51 P.-P. Part H Spring, Leaf, Simulator Asm H Pad, Spring, Leaf

- - - "Injection Molding, Small Size and/or Low Complexi $35.51 Tool H Pad, Spring, Leaf Injection Molding Machine 55-150 ton $35.51 Part H Pad, Spring, Leaf H Pad, Spring, Leaf - Material

- - - Raw Material Req 0.064 lbs from Cost Sheet

- - - 8 Cavity Mold

- - - Box Size 47mm L x 40mm W x 21mm H $35.51 Fastening H Simulator, Brake Pedal Asm Push In Place

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing $35.51 Subassembly H Simulator, Brake Pedal Asm H Spring, Rubber Bumper, Brake Pedal Asm $35.51 Tool H Spring, Rubber Bumper, Brake Pedal Asm First Fixture $16.39 P.-P. Part H Spring, Rubber Bumper, Brake Pedal Asm H Spring, Rubber Bumper, Brake Pedal - Molded $16.39 Tool H Spring, Rubber Bumper, Brake Pedal - Molded Injection Molding Machine 55-150 ton $16.39 Part H Spring, Rubber Bumper, Brake Pedal - Molded H Spring, Rubber Bumper, Brake Pedal - Material

- - - Raw Material Req 0.065 lbs from Cost Sheet

- - - 16 Cavity Mold

- - - Box Size (50x40x25)mm $35.51 P.-P. Part H Spring, Rubber Bumper, Brake Pedal Asm H Plate, Spring, Rubber Bumper $35.51 Tool H Plate, Spring, Rubber Bumper Stamping Press 0-60 Ton $35.51 Part H Plate, Spring, Rubber Bumper H Plate, Spring, Rubber Bumper, Material

- - - Blank weight 0.006 lbs

- - - Press Size 25 Ton Progressive

- - - Part Size after stamping (33x33x0.3)mm

- - - Hold together by hand - no adhesive or fasteners

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

# - - - Space for Printing

$55.17 P.-P. Part H Simulator, Brake Pedal Asm H Cover, Simulator, Brake Pedal $55.17 Tool H Cover, Simulator, Brake Pedal Anodizing Equipment $55.17 P.-P. Part H Cover, Simulator, Brake Pedal H Cover, Simulator, Brake Pedal - W ashed

- - - "W ashing, Small Size and/or Low Complexity" $55.17 Tool H Cover, Simulator, Brake Pedal - W ashed Wa sher Duo 400 W ash Rinse & DRY

- - - Batch Type W asher $55.17 P.-P. Part H Cover, Simulator, Brake Pedal - W ashed H Cover, Simulator, Brake Pedal - Deburred $55.17 Tool H Cover, Simulator, Brake Pedal - Deburred Deburing Equipment

- - - Deburr $55.17 P.-P. Part H Cover, Simulator, Brake Pedal - Deburred H Cover, Simulator, Brake Pedal - Stamped $55.17 Tool H Cover, Simulator, Brake Pedal - Stamped Stamping Press 0-60 Ton $55.17 Part H Cover, Simulator, Brake Pedal - Stamped H Cover, Simulator, Brake Pedal - Material

- - - Blank weight 0.387 lbs

- - - Press Size 60 Ton Progressive

- - - Part Size after stamping (103 L by 98 W by 2 H)mm

- - - Batch $55.17 Operation H Cover, Simulator, Brake Pedal - Deburred Load Part $55.17 Material Mod. H Cover, Simulator, Brake Pedal - Deburred Debur/Tumble $55.17 Operation H Cover, Simulator, Brake Pedal - Deburred Remove Part

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2 $55.17 Operation H Cover, Simulator, Brake Pedal - W ashed Load Part $55.17 Operation H Cover, Simulator, Brake Pedal - W ashed Wa sh Part Medium $55.17 Operation H Cover, Simulator, Brake Pedal - W ashed Unload Part $55.17 Operation H Cover, Simulator, Brake Pedal Load Part $55.17 Operation H Cover, Simulator, Brake Pedal Electroplate Process $55.17 Operation H Cover, Simulator, Brake Pedal Remove Part $35.51 Part H Simulator, Brake Pedal Asm H O-Ring, NVH, Simulator Shaft $35.51 Tool H Simulator, Brake Pedal Asm Nut Runner - Single $35.51 Part H Simulator, Brake Pedal Asm H Screw, Cover, Brake Pedal Spring, Primary $35.51 Fastening H Simulator, Brake Pedal Asm Power Screw $35.51 Fastening H Brake Pedal and Simulator Asm Push On $35.51 Fastening H Brake Pedal Assembly Power Screw $35.51 Operation H Brake Pedal Assembly CDI

- - - 2 Screws $35.51 Part H Brake Pedal Assembly H Screw, Brake Pedal Sensor $35.51 Tool H Brake Pedal Assembly Power Tool $35.51 Fastening H Brake Pedal Assembly Power Screw 

# Report Totals **Count:** ##

# Design Profit ®

Page 6 of 6

Copyright 2005© Munro & Associates, Inc.

# Number **Munro Actual Time**  **Piece Cost Total Labor**  **Qty**

**Score Cost**  **(Total)**

0.0000 sec 0.0000 sec $0.00 $0.00 1

- - - - - - H Bracket, Brake to Mounting Bracket 18.0000 sec 18.0000 sec

- $0.18 1

- - - - - - 3.0000 sec 3.0000 sec $0.00 $0.04 1

- - - - - - H Bracket, Brake to Mounting Bracket - Stamped 3.0000 sec 3.0000 sec

- $0.04 1

0.0000 sec 0.0000 sec $0.00 $0.00 1 H Bracket, Brake to Mounting Bracket - Material 0.0000 sec **1.8000 sec** $0.68 $0.02 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H W eld Nut, Bracket, Brake 3.0000 sec **3.0000 sec** $0.00 $0.04 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

H W eld Nut, Bracket, Brake 3.0000 sec **3.0000 sec** $0.00 $0.04 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

- - **-** - - - 4.0000 sec **4.0000 sec** $0.00 $0.04 1 H Bolt, Brake Mounting Bracket 6.0000 sec **6.0000 sec** $0.04 $0.06 2

4.0000 sec **4.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1

- - **-** - - - H Brake Mounting Bracket Asm. 6.0000 sec **6.0000 sec** $0.00 $0.06 1

- - **-** - - - H Bolt, Brake Mounting Bracket 6.0000 sec **6.0000 sec** $0.04 $0.06 2 H Brake Pedal Subassembly 11.0000 sec **11.0000 sec**

- $0.11 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

H Brake Position Sensor & Brkt Asm 10.0000 sec **10.0000 sec**

- $0.10 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

H Brake Position Sensor Asm 3.0000 sec **3.0000 sec** $0.00 $0.03 1

- - **-** - - - H Brake Position Sensor Bracket Asm 9.0000 sec **9.0000 sec**

- $0.09 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

H Brake Position Sensor Bracket - Molded 7.0000 sec **7.0000 sec**

- $0.03 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

H Brake Position Sensor Bracket - Material 0.0000 sec **1.7760 sec** $0.06 $0.01 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Brake Position Sensor Brkt Insert 3.0000 sec **3.0000 sec** $0.00 $0.01 2

3.0000 sec **3.0000 sec** $0.00 $0.01 1

H Brake Pedal Actuator Asm 8.0000 sec **8.0000 sec**

- $0.08 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

# H Housing, Actuator, Brake 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Housing, Actuator, Brake - Machined 3.0000 sec **3.0000 sec**

- $0.04 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Housing, Actuator, Brake - Cut Block 12.0000 sec **12.0000 sec**

- $0.20 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Housing, Actuator, Brake - Extrusion 0.0000 sec **0.0000 sec** $3.12 $0.00 1

4.0000 sec **4.0000 sec** $0.00 $0.03 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.05 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.5000 sec **2.5000 sec** $0.00 $0.04 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

# 2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.5000 sec **2.5000 sec** $0.00 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.04 1

5.0000 sec **5.0000 sec** $0.00 $0.07 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Ball, Stainless Steel, 3.4 mm 3.0000 sec **3.0000 sec** $0.00 $0.03 5

3.0000 sec **3.0000 sec** $0.00 $0.03 5

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1 H Coil, Magnetic, Brake Actuator 7.0000 sec **7.0000 sec** $0.00 $0.07 1
H Piston, Actuator, Brake 12.0000 sec **12.0000 sec**

- $0.12 2

0.0000 sec **0.0000 sec** $0.00 $0.00 2
H Piston, Actuator, W ashed 3.0000 sec **3.0000 sec**

- $0.03 2

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 2

- - **-** - - -

- - **-** - - -

- - **-** - - - H Piston, Actuator, Brake, Machined 3.0000 sec **3.0000 sec**

- $0.03 2

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 2
H Piston, Actuator, Brake - Material 0.0000 sec **0.0000 sec** $0.08 $0.00 2

- - **-** - - -

# - - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.02 2

3.0000 sec **3.0000 sec** $0.00 $0.02 2

1.0000 sec **1.0000 sec** $0.00 $0.01 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

1.0000 sec **1.0000 sec** $0.00 $0.01 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

1.0000 sec **1.0000 sec** $0.00 $0.01 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

1.0000 sec **1.0000 sec** $0.00 $0.01 2

1.0000 sec **1.0000 sec** $0.00 $0.01 2

3.0000 sec **3.0000 sec** $0.00 $0.02 2

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.02 2

5.0000 sec **5.0000 sec** $0.00 $0.04 2

1.0000 sec **1.0000 sec** $0.00 $0.01 2

3.0000 sec **3.0000 sec** $0.00 $0.03 2

5.0000 sec **5.0000 sec** $0.00 $0.05 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2 H O-Ring, Piston, Actuator 8.0000 sec **8.0000 sec** $0.08 $0.08 2

2.0000 sec **2.0000 sec** $0.00 $0.02 2

- - **-** - - - H Spring, Coil, Piston, Actuator, Br 8.0000 sec **8.0000 sec** $0.07 $0.08 1 H Cap, Piston Spring Asm 2.0000 sec **2.0000 sec**

- $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Cap, Rim, Stamped 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Cap, Rim - Material 0.0000 sec **0.6000 sec** $0.01 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Cap, Button, Molded 6.0000 sec **6.0000 sec** $0.00 $0.06 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1



# Number **Munro Actual Time**  **Piece Cost Total Labor**  **Qty**

**Score Cost**  **(Total)**

3.0000 sec **3.0000 sec** $0.00 $0.03 1 H C-Clip, Brake Actuator Piston 6.0000 sec **6.0000 sec** $0.00 $0.06 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1
H Label, Brake Pedal Actuator Asm 17.0000 sec **17.0000 sec** $0.10 $0.17 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1
H Fluid, Actuator, Brake 4.0000 sec **4.0000 sec** $0.00 $0.04 1

10.0000 sec **10.0000 sec** $0.00 $0.10 1

# H Plunger Asm, Brake, Actuator 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Shaft, Actuator, Brake 3.0000 sec **3.0000 sec**

- $0.03 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Shaft, Actuator, Brake - Machined 3.0000 sec **3.0000 sec**

- $0.03 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Shaft, Actuator, Brake - Material 0.0000 sec **0.0000 sec** $1.05 $0.00 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.05 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1 H Bell Housing, Actuator, Brake 6.0000 sec **6.0000 sec**

- $0.06 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Bell Housing, Actuator, Brake - Machined 3.0000 sec **3.0000 sec**

- $0.02 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Bell Housing, Actuator, Brake - Material 1.0000 sec **1.0000 sec** $0.06 $0.01 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

# 1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1

H Foam W iper, Actuator, Brake 2.0000 sec **2.0000 sec** $0.01 $0.02 1 H Cap, Plunger, Actuator 6.0000 sec **0.6000 sec**

- $0.01 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Cap, Plunger, Actuator - Material 0.0000 sec **0.0000 sec** $0.02 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Stud and O-Ring Asm, Actuator 2.0000 sec **2.0000 sec**

- $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Stud, Threaded, Actuator, Brake 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Stud, Threaded, Actuator, Brake - Machined 3.0000 sec **3.0000 sec**

- $0.05 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - -

# H Stud, Threaded, Actuator, Brake - Material 0.0000 sec **0.0000 sec** $0.36 $0.00 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.19 1

3.0000 sec **3.0000 sec** $0.00 $0.19 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

3.0000 sec **3.0000 sec** $0.00 $0.19 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

3.0000 sec **3.0000 sec** $0.00 $0.19 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

3.0000 sec **3.0000 sec** $0.00 $0.19 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

3.0000 sec **3.0000 sec** $0.00 $0.19 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

3.0000 sec **3.0000 sec** $0.00 $0.19 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

2.0000 sec **2.0000 sec** $0.00 $0.13 1

1.0000 sec **1.0000 sec** $0.00 $0.06 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

10.0000 sec **10.0000 sec** $0.00 $0.15 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1 H O-Ring, Stud, Actuator, Brake 4.0000 sec **4.0000 sec** $0.07 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1 H Retainer, Plunger, Actuator, Brake 3.0000 sec **3.0000 sec**

- $0.03 1 H Retainer, Plunger, Actuator, Brake 3.0000 sec **3.0000 sec**

0.0000 sec **0.0000 sec** $0.00 $0.00 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Retainer, Plunger, Actuator, Brake - Machined 3.0000 sec **3.0000 sec**

- $0.05 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Retainer, Plunger, Actuator, Brake - Material 0.0000 sec **0.0000 sec** $0.21 $0.00 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

# 1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

10.0000 sec **10.0000 sec** $0.00 $0.15 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

H W ire, Retaining, Plunger, Brake, Actuator 5.0000 sec **5.0000 sec** $0.01 $0.05 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1 H Spring, Coil, Actuator, Brake 8.0000 sec **8.0000 sec** $0.95 $0.08 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1 H Snap Ring - Actuator, Brake 6.0000 sec **6.0000 sec** $0.00 $0.06 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1
H Nut, Lock, Actuator, Brake 6.0000 sec **6.0000 sec** $0.00 $0.06 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1

- - **-** - - -

- - **-** - - -



# Number **Munro Actual Time**  **Piece Cost Total Labor**  **Qty**

**Score Cost**  **(Total)**

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Clevis, Actuator, Brake 6.0000 sec **6.0000 sec**

- $0.06 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

# - - **-** - - -

- - **-** - - -

- - **-** - - - H Clevis, Actuator, Brake, Machined 3.0000 sec **3.0000 sec**

- $0.01 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Clevis, Actuator, Brake - Turned 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - -

- - **-** - - - H Clevis, Actuator, Brake, Material 0.0000 sec **0.0000 sec** $0.40 $0.00 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

4.0000 sec **4.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.06 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.01 1

5.0000 sec **5.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1
H Sensor, Pressure, Brake Pedal 6.0000 sec **6.0000 sec** $10.00 $0.06 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1
H Screw, Brake Actuator 5.0000 sec **5.0000 sec** $0.07 $0.05 2

4.0000 sec **4.0000 sec** $0.00 $0.04 1

4.0000 sec **4.0000 sec** $0.00 $0.04 2 H Clip, Spring, Brake Pedal Simulator 7.0000 sec **7.0000 sec** $0.00 $0.07 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.05 1 H Spring, Coil, Brake Pedal Return 10.0000 sec **10.0000 sec** $0.07 $0.10 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

# - - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

# - - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Pivot, Brake Pedal Return Spring - Molded 6.0000 sec **6.0000 sec**

- $0.06 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Pivot, Brake Pedal Return Spring - Material 0.0000 sec **28.5040 sec** $0.05 $0.13 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Latch, Brake Pedal Return Spring - Molded 7.0000 sec **7.0000 sec**

- $0.07 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Latch, Brake Pedal Return Spring - Material 0.0000 sec **2.5850 sec** $0.05 $0.01 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 5.0000 sec **5.0000 sec** $0.00 $0.05 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Pin, Brake, Pivot, Main 9.0000 sec **9.0000 sec**

- $0.09 1 H Pin, Brake, Pivot, Main 9.0000 sec **9.0000 sec**

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Pin, Brake, Pivot, Machined 3.0000 sec **3.0000 sec**

- $0.01 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Pin, Brake, Pivot, Material 0.0000 sec **0.0000 sec** $0.31 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - 1.0000 sec **1.0000 sec** $0.00 $0.01 2

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

# 1.0000 sec **1.0000 sec** $0.00 $0.01 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.03 1

- - **-** - - - 3.0260 sec **1.8156 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - -

- - **-** - - -



# Number **Munro Actual Time**  **Piece Cost Total Labor**  **Qty**

**Score Cost**  **(Total)**

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.01 1

5.0000 sec **5.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1
H Bracket, Brake Pedal 3.0000 sec **3.0000 sec**

- $0.03 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - -

- - **-** - - - H Bracket, Brake Pedal Machined 2.0000 sec **2.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Bracket, Brake Pedal Casting - Trimmed 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Bracket, Brake Pedal Casting 0.0000 sec **16.3800 sec**

- $0.14 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Bracket, Brake Pedal Casting - Material 0.0000 sec **17.0800 sec** $2.52 $0.93 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

# 3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - - 5.0000 sec **5.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

5.0000 sec **5.0000 sec** $0.00 $0.04 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - - 5.0000 sec **5.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

5.0000 sec **5.0000 sec** $0.00 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - - 1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - - 1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - - 1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

5.0000 sec **5.0000 sec** $0.00 $0.07 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1
H Pushnut, Fastener 3.0000 sec **3.0000 sec** $0.01 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

4.0000 sec **4.0000 sec** $0.00 $0.04 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

# - - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Screw - Brake Pedal, Stoplight Switch Brkt 6.0000 sec **6.0000 sec** $0.01 $0.06 1 H Bracket, Brake Pedal Brakelight Switch 5.0000 sec **5.0000 sec**

- $0.05 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Bracket, Brake Pedal Brakelight Switch Material 0.0000 sec **1.7000 sec** $0.13 $0.02 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 4.0000 sec **4.0000 sec** $0.00 $0.04 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Brake Pedal and Simulator Asm 9.0000 sec **9.0000 sec**

- $0.09 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Brake Pedal Arm Subassembly 5.0000 sec **5.0000 sec**

- $0.05 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Brake Pedal Arm, W eldment, Painted 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.05 1
H Brake Pedal Arm, W eldment, W ashed 7.0000 sec **7.0000 sec**

- $0.11 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Brake Pedal Arm, W eldment, Machined 3.0000 sec **3.0000 sec**

- $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.04 1
H Brake Pedal, Partial W eldment, Machined 3.0000 sec **3.0000 sec**

- $0.04 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

H Brake Pedal Arm Partial W eldment 2.0000 sec **2.0000 sec**

- $0.06 1

# 3.0000 sec **3.0000 sec** $0.00 $0.04 1

- - **-** - - - H Brake Pedal Arm, Swaged 3.0000 sec **3.0000 sec**

- $0.04 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Brake Pedal Arm Partial W eldment (stage 1) 2.0000 sec **2.0000 sec**

- $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Brake Pedal Arm Stamping 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Brake Pedal Arm Material 0.0000 sec **1.8000 sec** $5.10 $0.02 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1 H Pin, Brake Pedal Spring Pivot 2.0000 sec **2.0000 sec**

- $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Pin, Brake Pedal Spring Pivot - Machined 3.0000 sec **3.0000 sec**

- $0.01 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Pin, Brake Pedal Spring Pivot - Material 0.0000 sec **0.0000 sec** $0.42 $0.00 1

- - **-** - - -

- - **-** - - - 1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1

- - **-** - - -

- - **-** - - -

# Number **Munro Actual Time**  **Piece Cost Total Labor**  **Qty**

**Score Cost**  **(Total)**

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.01 1

5.0000 sec **5.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1
H Tube, Pivot, Brake Pedal Arm 3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Bar, Brake Pedal Spring 3.0000 sec **3.0000 sec**

- $0.04 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Bar, Brake Pedal Spring - machined 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1 H Bar, Brake Pedal Spring - cut 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Bar, Brake Pedal Spring - bar stock 0.0000 sec **0.0000 sec** $0.14 $0.00 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.05 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.10 1

3.0000 sec **3.0000 sec** $0.00 $0.10 1

# - - **-** - - - 1.0000 sec **1.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.06 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.10 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.06 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1 H Bracket, Brake Pedal Stop 3.0000 sec **3.0000 sec**

- $0.04 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Bracket, Brake Pedal Stop - Material 0.0000 sec **0.7000 sec** $0.13 $0.01 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1
H Pedal Contact, Brake Pedal 6.0000 sec **6.0000 sec**

- $0.07 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Pedal Contact, Brake Pedal, Raw Material 0.0000 sec **0.6000 sec** $0.19 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.04 1

1.0000 sec **1.0000 sec** $0.00 $0.01 3

3.0000 sec **3.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1
H Bumper, Brake Pedal 4.0000 sec **4.0000 sec** $0.01 $0.04 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1 H Bushing, Brake Pedal Pivot 10.0000 sec **10.0000 sec** $0.38 $0.10 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - -

- - **-** - - - H Contact Cover, Brake Pedal 6.0000 sec **6.0000 sec**

- $0.06 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Contact Cover, Brake Pedal, Raw Material 0.0000 sec **19.7350 sec** $0.19 $0.16 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 7.0000 sec **7.0000 sec** $0.00 $0.07 1

- - **-** - - -

- - **-** - - -

# - - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Simulator, Brake Pedal Asm 8.0000 sec **8.0000 sec**

- $0.08 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Housing, Simlator, Brake Pedal 3.0000 sec **3.0000 sec**

- $0.03 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Housing Asm, Brake, Simulator 3.0000 sec **3.0000 sec**

- $0.03 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Housing, Simulator, Brake - Machined 3.0000 sec **3.0000 sec**

- $0.02 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Housing, Simulator, Brake - Casting 3.0000 sec **3.0000 sec**

- $0.05 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Pin, Simulator - Actuator 3.0000 sec **3.0000 sec**

- $0.21 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Pin, Simulator - Actuator - W ashed 3.0000 sec **3.0000 sec**

- $0.05 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Pin, Simulator - Actuator - Machined 3.0000 sec **3.0000 sec**

- $0.01 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H PIn, Simulator - Actuator - Material 0.0000 sec **0.0000 sec** $0.04 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

# 1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.01 1

5.0000 sec **5.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

- - **-** - - -

- - **-** - - - 3.0260 sec **1.8156 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

- - **-** - - - H Housing, Simulator, Brake - Material 0.0000 sec **7.8800 sec** $1.05 $0.54 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.05 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1



# Number **Munro Actual Time**  **Piece Cost Total Labor**  **Qty**

**Score Cost**  **(Total)**

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

# 2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

1.0000 sec **1.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.02 1

5.0000 sec **5.0000 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.01 1 H Pin, Dowel, Split, Simulator Housing 6.0000 sec **6.0000 sec** $0.03 $0.06 2

1.0000 sec **1.0000 sec** $0.00 $0.01 1

3.0000 sec **3.0000 sec** $0.00 $0.03 2 H Bushing, Brake Simulator Housing 6.0000 sec **6.0000 sec** $0.14 $0.06 2

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

3.0000 sec **3.0000 sec** $0.00 $0.03 1

1.0000 sec **1.0000 sec** $0.00 $0.01 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

2.0000 sec **2.0000 sec** $0.00 $0.02 1 H Bumper, Leaf Spring, Simulator 2.0000 sec **2.0000 sec**

- $0.02 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Bumper, Leaf Spring, Simulator - Material 0.0000 sec **9.2400 sec** $0.01 $0.04 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

# - - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Spring, Leaf, Simulator Asm 2.0000 sec **2.0000 sec**

- $0.02 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Spring, Leaf, Simulator 2.0000 sec **2.0000 sec** $0.00 $0.02 1 H Pad #2, Leaf Spring 6.0000 sec **6.0000 sec**

- $0.06 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Pad #2, Leaf Spring - Material 0.0000 sec **0.6840 sec** $0.00 $0.01 1

- - **-** - - -

- - **-** - - -

- - **-** - - - H Pad, Spring, Leaf 11.0000 sec **11.0000 sec**

- $0.11 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Pad, Spring, Leaf - Material 0.0000 sec **4.7400 sec** $0.10 $0.05 1

- - **-** - - -

- - **-** - - -

- - **-** - - - 2.0000 sec **2.0000 sec** $0.00 $0.02 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - H Spring, Rubber Bumper, Brake Pedal Asm 8.0000 sec **8.0000 sec**

- $0.08 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Spring, Rubber Bumper, Brake Pedal - Molded 8.0000 sec **8.0000 sec**

- $0.08 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Spring, Rubber Bumper, Brake Pedal - Material 0.0000 sec **136.1500** $0.12 $0.62 1

**sec**

- - **-** - - -

- - **-** - - -

- - **-** - - - H Plate, Spring, Rubber Bumper 8.0000 sec **8.0000 sec**

- $0.08 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1 H Plate, Spring, Rubber Bumper, Material 0.0000 sec **0.0600 sec** $0.01 $0.00 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - -

# - - **-** - - -

H Cover, Simulator, Brake Pedal 6.0000 sec **6.0000 sec**

- $0.06 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Cover, Simulator, Brake Pedal - W ashed 3.0000 sec **3.0000 sec**

- $0.05 1

- - **-** - - - 0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Cover, Simulator, Brake Pedal - Deburred 3.0000 sec **3.0000 sec**

- $0.05 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1

- - **-** - - - H Cover, Simulator, Brake Pedal - Stamped 3.0000 sec **3.0000 sec**

- $0.05 1

0.0000 sec **0.0000 sec** $0.00 $0.00 1
H Cover, Simulator, Brake Pedal - Material 0.0000 sec **0.7000 sec** $0.21 $0.01 1

- - **-** - - -

- - **-** - - -

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.05 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

- - **-** - - -

- - **-** - - - 3.0000 sec **3.0000 sec** $0.00 $0.05 1

5.0000 sec **5.0000 sec** $0.00 $0.08 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1

3.0000 sec **3.0000 sec** $0.00 $0.05 1

3.0260 sec **1.8156 sec** $0.00 $0.03 1

2.0000 sec **2.0000 sec** $0.00 $0.03 1 H O-Ring, NVH, Simulator Shaft 4.0000 sec **4.0000 sec** $0.00 $0.04 3

3.0000 sec **3.0000 sec** $0.00 $0.03 1
H Screw, Cover, Simulator, Brake Pedal 2.0000 sec **2.0000 sec** $0.00 $0.02 2

4.0000 sec **4.0000 sec** $0.00 $0.04 2

2.0000 sec **2.0000 sec** $0.00 $0.02 1

4.0000 sec **4.0000 sec** $0.00 $0.04 2

1.0000 sec **1.0000 sec** $0.00 $0.01 1

- - **-** - - - H Screw, Brake Pedal Sensor 5.0000 sec **5.0000 sec** $0.06 $0.05 2

4.0000 sec **4.0000 sec** $0.00 $0.04 1

4.0000 sec **4.0000 sec** $0.00 $0.04 2

**776**

# Piece Cost **Total Labor Cost**

**(Total) (Total)**  $0.00 $0.00

- -

- $0.18

- - $0.00 $0.04

- -

- $0.04
$0.00 $0.00
$0.68 $0.02

- -

- -

- -

- - $0.00 $0.04
$0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.04

- - $0.00 $0.04
$0.08 $0.12
$0.00 $0.04
$0.00 $0.01
$0.00 $0.04

- - $0.00 $0.06

- - $0.08 $0.12

- $0.11
$0.00 $0.00

- $0.10
$0.00 $0.00
$0.00 $0.03

- -

- $0.09
$0.00 $0.00

- $0.03

- - $0.00 $0.00
$0.06 $0.01

- -

- -

- - $0.00 $0.03
$0.00 $0.01

- $0.08
$0.00 $0.00

# - $0.03
$0.00 $0.00

- -

- $0.04

- - $0.00 $0.00

- $0.20
$0.00 $0.00
$3.12 $0.00
$0.00 $0.03

- -

- - $0.00 $0.05
$0.00 $0.05
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.05
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.03
$0.00 $0.05
$0.00 $0.02
$0.00 $0.03
$0.00 $0.04
$0.00 $0.05
$0.00 $0.02
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03

# $0.00 $0.03
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.05
$0.00 $0.02
$0.00 $0.03
$0.00 $0.04
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.02
$0.00 $0.00
$0.00 $0.05
$0.00 $0.05
$0.00 $0.03
$0.00 $0.02
$0.00 $0.00
$0.00 $0.05
$0.00 $0.05
$0.00 $0.08
$0.00 $0.02

- -

- - $0.00 $0.04
$0.00 $0.07
$0.00 $0.03
$0.00 $0.00
$0.00 $0.15
$0.00 $0.15
$0.00 $0.01
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.07

- $0.24
$0.00 $0.00

- $0.06

- - $0.00 $0.00

- -

- -

- -

- $0.06

- - $0.00 $0.00
$0.16 $0.00

- -

# - - $0.00 $0.05
$0.00 $0.05
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.02
$0.00 $0.02
$0.00 $0.05

- - $0.00 $0.05
$0.00 $0.08
$0.00 $0.02
$0.00 $0.06
$0.00 $0.10
$0.00 $0.04
$0.15 $0.16
$0.00 $0.04

- - $0.07 $0.08

- $0.02
$0.00 $0.00

- $0.03
$0.00 $0.00
$0.01 $0.00

- -



# - -

- - $0.00 $0.06
$0.00 $0.01
$0.00 $0.03



# Piece Cost **Total Labor Cost**

**(Total) (Total)**  $0.00 $0.03
$0.00 $0.06
$0.00 $0.02
$0.00 $0.03
$0.10 $0.17
$0.00 $0.02
$0.00 $0.04
$0.00 $0.04
$0.00 $0.10

# - $0.03
$0.00 $0.00

- $0.03

- - $0.00 $0.00

- -

- -

- -

- $0.03

- - $0.00 $0.00

- - $1.05 $0.00

- -

- - $0.00 $0.02
$0.00 $0.02
$0.00 $0.04
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.04
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.03
$0.00 $0.05
$0.00 $0.02

- $0.06

- - $0.00 $0.00

- -

- -

- -

- $0.02

- - $0.00 $0.00

- - $0.06 $0.01

- -

- - $0.00 $0.02
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02

# $0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.01
$0.00 $0.02
$0.00 $0.02
$0.00 $0.04
$0.00 $0.02
$0.00 $0.04
$0.00 $0.01

- - $0.00 $0.02
$0.00 $0.03
$0.00 $0.01
$0.01 $0.02

- $0.01
$0.00 $0.00
$0.02 $0.00

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- $0.02
$0.00 $0.00

- $0.03
$0.00 $0.00

- $0.05
$0.00 $0.00

- -

# $0.36 $0.00

- -

- - $0.00 $0.19
$0.00 $0.19
$0.00 $0.13
$0.00 $0.13
$0.00 $0.13
$0.00 $0.13
$0.00 $0.06
$0.00 $0.19
$0.00 $0.06
$0.00 $0.19
$0.00 $0.06
$0.00 $0.19
$0.00 $0.06
$0.00 $0.19
$0.00 $0.06
$0.00 $0.19
$0.00 $0.06
$0.00 $0.13
$0.00 $0.13
$0.00 $0.13
$0.00 $0.06
$0.00 $0.13
$0.00 $0.06
$0.00 $0.05
$0.00 $0.15
$0.00 $0.08
$0.00 $0.03
$0.07 $0.04
$0.00 $0.02

- $0.03
$0.00 $0.00
$0.00 $0.00

- $0.05

- - $0.00 $0.00

- - $0.21 $0.00

- -

- - $0.00 $0.02
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.01
$0.00 $0.02
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02

# $0.00 $0.01
$0.00 $0.01
$0.00 $0.05
$0.00 $0.15
$0.00 $0.08
$0.00 $0.03
$0.00 $0.00
$0.00 $0.01
$0.00 $0.00
$0.01 $0.05
$0.00 $0.04
$0.00 $0.01
$0.00 $0.03
$0.00 $0.02
$0.95 $0.08
$0.00 $0.03
$0.00 $0.03
$0.00 $0.06
$0.00 $0.02
$0.00 $0.04
$0.00 $0.06
$0.00 $0.04

- -

- -



# Piece Cost **Total Labor Cost**

**(Total) (Total)** 

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- $0.06

- - $0.00 $0.00

# - -

- -

- -

- $0.01
$0.00 $0.00

- $0.03
$0.00 $0.00

- -

- - $0.40 $0.00

- -

- - $0.00 $0.02
$0.00 $0.02
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.01
$0.00 $0.03
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.06
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.04
$0.00 $0.04
$10.00 $0.06
$0.00 $0.04
$0.15 $0.10
$0.00 $0.04
$0.00 $0.08
$0.00 $0.07
$0.00 $0.03
$0.00 $0.05
$0.07 $0.10

- -

- -

- -

- -

- -

- -

- -

- -

# - -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

# - -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- $0.06

- - $0.00 $0.00
$0.05 $0.13

- -

- -

- -

- -

- $0.07

- - $0.00 $0.00
$0.05 $0.01

- -

- -

- - $0.00 $0.05

- -

- -

- -

- -

- -

- $0.09

- - $0.00 $0.00

- $0.01

- - $0.00 $0.00

- - $0.31 $0.00

- -

- -

- -

- - $0.00 $0.02
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02

# $0.00 $0.01

- - $0.00 $0.00

- - $0.00 $0.03

- - $0.00 $0.02
$0.00 $0.02

- -

- -



# Piece Cost **Total Labor Cost**

**(Total) (Total)** 

- - $0.00 $0.01
$0.00 $0.01
$0.00 $0.01

- $0.03

- - $0.00 $0.00

- -

- -

- $0.03
$0.00 $0.00

- -

- $0.03
$0.00 $0.00

- $0.14

- - $0.00 $0.00

- - $2.52 $0.93

- -

- -

- - $0.00 $0.03
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01

# $0.00 $0.03
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.03
$0.00 $0.01
$0.00 $0.02

- - $0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.03
$0.00 $0.04
$0.00 $0.02

- - $0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.02

- - $0.00 $0.01
$0.00 $0.02

- - $0.00 $0.01
$0.00 $0.02

- - $0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.04
$0.00 $0.07
$0.00 $0.03
$0.00 $0.00
$0.00 $0.03
$0.00 $0.03
$0.01 $0.03
$0.00 $0.03
$0.00 $0.04

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

# - -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- - $0.01 $0.06

- $0.05
$0.00 $0.00
$0.13 $0.02

- -

- -

- - $0.00 $0.04

- -

- -

- -

- $0.09
$0.00 $0.00

- $0.05
$0.00 $0.00

- -

- $0.03
$0.00 $0.00

- - $0.00 $0.05

- $0.11
$0.00 $0.00

- -

- $0.02
$0.00 $0.04

- - $0.00 $0.04

- $0.04
$0.00 $0.00

- $0.06

# $0.00 $0.04

- -

- $0.04
$0.00 $0.00

- -

- $0.02
$0.00 $0.00

- -

- $0.03
$0.00 $0.00

- - $5.10 $0.02

- -

- -

- - $0.00 $0.03
$0.00 $0.03
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.02
$0.00 $0.02
$0.00 $0.01
$0.00 $0.02
$0.00 $0.01


# $0.00 $0.03

- $0.02
$0.00 $0.00

- $0.01
$0.00 $0.00

- - $0.42 $0.00

- -

- - $0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01

- -

- -

# Piece Cost **Total Labor Cost**

**(Total) (Total)** 

- - $0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.01
$0.00 $0.04

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- $0.04
$0.00 $0.00

- -

- $0.03
$0.00 $0.00

- - $0.00 $0.03
$0.00 $0.03

- $0.03
$0.00 $0.00

- - $0.14 $0.00
$0.00 $0.01
$0.00 $0.00
$0.00 $0.03
$0.00 $0.01
$0.00 $0.01

- -

- -

- - $0.00 $0.03
$0.00 $0.05
$0.00 $0.02
$0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.01

- - $0.00 $0.10
$0.00 $0.10

# - - $0.00 $0.03
$0.00 $0.06
$0.00 $0.03
$0.00 $0.10
$0.00 $0.03
$0.00 $0.06
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.04

- $0.04
$0.00 $0.00

- - $0.13 $0.01

- -

- -

- - $0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.04

- $0.07
$0.00 $0.00
$0.19 $0.00

- -

- -

- - $0.00 $0.04
$0.00 $0.01
$0.00 $0.04
$0.00 $0.04
$0.00 $0.02
$0.00 $0.03
$0.00 $0.01
$0.00 $0.03
$0.01 $0.04
$0.00 $0.02
$0.38 $0.10
$0.00 $0.02

- -

- -

- $0.06
$0.00 $0.00
$0.19 $0.16

- -

- -

- - $0.00 $0.07

- -

- -

# - -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- $0.08
$0.00 $0.00

- $0.03
$0.00 $0.00

- -

- $0.03

- - $0.00 $0.00

- -

- -

- -

- $0.02

- - $0.00 $0.00

- $0.05
$0.00 $0.00

- -

- $0.21
$0.00 $0.00

- -

- $0.05

- - $0.00 $0.00

- -

- -

- -

- $0.01

- - $0.00 $0.00

- - $0.04 $0.00

- -

- -

- - $0.00 $0.01
$0.00 $0.01

# $0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.01
$0.00 $0.05

- -

- - $0.00 $0.03
$0.00 $0.03

- - $1.05 $0.54

- -

- -

- - $0.00 $0.05
$0.00 $0.05
$0.00 $0.08
$0.00 $0.03
$0.00 $0.08
$0.00 $0.03
$0.00 $0.08
$0.00 $0.03
$0.00 $0.08


# $0.00 $0.03
$0.00 $0.08
$0.00 $0.02
$0.00 $0.08
$0.00 $0.03



# Piece Cost **Total Labor Cost**

**(Total) (Total)**  $0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02
$0.00 $0.03
$0.00 $0.02

# $0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.03
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.05
$0.00 $0.03
$0.00 $0.03
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.02
$0.00 $0.03
$0.00 $0.01
$0.06 $0.12
$0.00 $0.01
$0.00 $0.06
$0.28 $0.12
$0.00 $0.01
$0.00 $0.02
$0.00 $0.03
$0.00 $0.01
$0.00 $0.02
$0.00 $0.00
$0.00 $0.02

- $0.02

- - $0.00 $0.00
$0.01 $0.04

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

# - -

- -

- -

- -

- -

- -

- $0.02
$0.00 $0.00
$0.00 $0.02

- $0.06

- - $0.00 $0.00
$0.00 $0.01

- -

- -

- -

- $0.11

- - $0.00 $0.00
$0.10 $0.05

- -

- -

- - $0.00 $0.02

- -

- -

- -

- -

- -

- -

- -

- -

- -

- $0.08
$0.00 $0.00

- $0.08
$0.00 $0.00
$0.12 $0.62

- -

- -

- -

- $0.08
$0.00 $0.00
$0.01 $0.00

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

- -

# - -

- $0.06
$0.00 $0.00

- $0.05

- - $0.00 $0.00

- -

- $0.05
$0.00 $0.00

- -

- $0.05
$0.00 $0.00
$0.21 $0.01

- -

- -

- -

- - $0.00 $0.05
$0.00 $0.05
$0.00 $0.03

- -

- - $0.00 $0.05
$0.00 $0.08
$0.00 $0.03
$0.00 $0.05
$0.00 $0.03
$0.00 $0.03
$0.00 $0.12
$0.00 $0.03
$0.00 $0.04
$0.00 $0.08
$0.00 $0.02
$0.00 $0.08
$0.00 $0.01

- - $0.12 $0.10
$0.00 $0.04
$0.00 $0.08

**$29.49 $25.15** 

# Indented Bill of Materials

**H Brake Pedal A**

**ssembly**

**Level Sy**  **mbol Name Number** 

**H Bracket, Brake to Mounting Bracket H Bracket, Brake to Mounting Bracket** 

**1 H Bracket, Brake to Mounting Bracket - Stamped**  **H Bracket, Brake to Mounting Bracket - Stamped**

**2** H Bracket, Brake to Mounting Bracket - Material H Bracket, Brake to Mounting Bracket - Material

1 H W eld Nut, Bracket, Brake H W eld Nut, Bracket, Brake

1 H W eld Nut, Bracket, Brake H W eld Nut, Bracket, Brake

0 H Bolt, Brake Mounting Bracket H Bolt, Brake Mounting Bracket

**0 H Brake Mounting Bracket A**  **sm. H Brake Mounting Bracket A**  **sm.**
**0** H Bolt, Brake Mounting Bracket H Bolt, Brake Mounting Bracket

**0 H Brake Pedal Subassembly**  **H Brake Pedal Subassembly**

**1 H Brake Position Sensor & Brkt A**  **sm H Brake Position Sensor & Brkt A**  **sm**
**2 H Brake Position Sensor A**  **sm H Brake Position Sensor A**  **sm**
**2 H Brake Position Sensor Bracket A**  **sm H Brake Position Sensor Bracket A**  **sm**
**3 H Brake Position Sensor Bracket - Molded**  **H Brake Position Sensor Bracket - Molded**

**4** H Brake Position Sensor Bracket - Material H Brake Position Sensor Bracket - Material

**3 H Brake Position Sensor Brkt Insert**  **H Brake Position Sensor Brkt Insert**

**1 H Brake Pedal A**  **ctuator A**

**sm H Brake Pedal A**  **ctuator A**

**sm**
**2 H Housing, A** 

**ctuator, Brake H Housing, A**  **ctuator, Brake**

**3 H Housing, A** 

**ctuator, Brake - Machined H Housing, A**  **ctuator, Brake - Machined**

**4 H Housing, A** 

**ctuator, Brake - Cut Block H Housing, A**  **ctuator, Brake - Cut Block**

**5** H Housing, Actuator, Brake - Extrusion H Housing, Actuator, Brake - Extrusion

2 H Ball, Plug, Stainless Steel, 3.4 mm H Ball, Stainless Steel, 3.4 mm

**2 H Coil, Magnetic, Brake A**  **ctuator H Coil, Magnetic, Brake A**  **ctuator**

**2 H Piston, A** 

**ctuator, Brake H Piston, A**  **ctuator, Brake**

**3 H Piston, A** 

**ctuator, Washed H Piston, A**  **ctuator, Washed**

**4 H Piston, A** 

**ctuator, Brake, Machined H Piston, A**  **ctuator, Brake, Machined**

**5** H Piston, Actuator, Brake - Material H Piston, Actuator, Brake - Material

**3 H O-Ring, Piston, A**  **ctuator H O-Ring, Piston, A**  **ctuator**

**2 H Spring, Coil, Piston, A**  **ctuator, Brake H Spring, Coil, Piston, A**  **ctuator, Br**

**2 H Cap, Piston Spring A**  **sm H Cap, Piston Spring A**  **sm**
**3 H Cap, Rim, Stamped**  **H Cap, Rim, Stamped**

**4** H Cap, Rim - Material H Cap, Rim - Material

**3 H Cap, Button, Molded**  **H Cap, Button, Molded**

**2** H C-Clip, Brake Actuator Piston H C-Clip, Brake Actuator Piston

2 H Label, Brake Pedal Actuator Asm H Label, Brake Pedal Actuator Asm

2 H Fluid, Actuator, Brake H Fluid, Actuator, Brake

**2 H Plunger A** 

**sm, Brake, A**

**ctuator H Plunger A**  **sm, Brake, A**

**ctuator**

**3 H Shaft, A** 

**ctuator, Brake H Shaft, A**  **ctuator, Brake**

**4 H Shaft, A** 

**ctuator, Brake - Machined H Shaft, A**  **ctuator, Brake - Machined**

**5** H Shaft, Actuator, Brake - Material H Shaft, Actuator, Brake - Material

**3 H Bell Housing, A**  **ctuator, Brake H Bell Housing, A**  **ctuator, Brake**

**4 H Bell Housing, A**  **ctuator, Brake - Machined H Bell Housing, A**  **ctuator, Brake - Machined**

**5** H Bell Housing, Actuator, Brake - Material H Bell Housing, Actuator, Brake - Material

**3 H Foam Wiper, A**  **ctuator, Brake H Foam Wiper, A**  **ctuator, Brake**

**3 H Cap, Plunger, A**  **ctuator H Cap, Plunger, A**  **ctuator**

**4** H Cap, Plunger, Actuator - Material H Cap, Plunger, Actuator - Material

**3 H Stud and O-Ring A**  **sm, A ctuator**  **H Stud and O-Ring A sm, A**  **ctuator**

# 4 **H Stud, Threaded, A ctuator, Brake**  **H Stud, Threaded, A ctuator, Brake** 

**5 H Stud, Threaded, A**  **ctuator, Brake - Machined H Stud, Threaded, A**  **ctuator, Brake - Machined**

**6** H Stud, Threaded, Actuator, Brake - Material H Stud, Threaded, Actuator, Brake - Material

4 H O-Ring, Stud, Actuator, Brake H O-Ring, Stud, Actuator, Brake

**4 H Retainer, Plunger, A**  **ctuator, Brake H Retainer, Plunger, A**  **ctuator, Brake**

**5 H Retainer, Plunger, A**  **ctuator, Brake - Machined H Retainer, Plunger, A**  **ctuator, Brake - Machined**

**6** H Retainer, Plunger, Actuator, Brake - Material H Retainer, Plunger, Actuator, Brake - Material

2 H W ire, Retaining, Plunger, Brake, Actuator H W ire, Retaining, Plunger, Brake, Actuator

**2 H Spring, Coil, A**  **ctuator, Brake H Spring, Coil, A**  **ctuator, Brake**

**2** H Snap Ring - Actuator, Brake H Snap Ring - Actuator, Brake

2 H Nut, Lock, Actuator, Brake H Nut, Lock, Actuator, Brake

**2 H Clevis, A** 

**ctuator, Brake H Clevis, A**  **ctuator, Brake**

**3 H Clevis, A** 

**ctuator, Brake, Machined H Clevis, A**  **ctuator, Brake, Machined**

**4 H Clevis, A** 

**ctuator, Brake - Turned H Clevis, A**  **ctuator, Brake - Turned**

**5** H Clevis, Actuator, Brake, Material H Clevis, Actuator, Brake, Material

**2 H Sensor, Pressure, Brake Pedal**  **H Sensor, Pressure, Brake Pedal**

**1** H Screw, Brake Actuator H Screw, Brake Actuator

1 H Clip, Spring, Brake Pedal Simulator H Clip, Spring, Brake Pedal Simulator

1 H Spring, Coil, Brake Pedal Return H Spring, Coil, Brake Pedal Return

**1 H Pivot, Brake Pedal Return Spring - Molded**  **H Pivot, Brake Pedal Return Spring - Molded**

**2** H Pivot, Brake Pedal Return Spring - Material H Pivot, Brake Pedal Return Spring - Material

**1 H Latch, Brake Pedal Return Spring - Molded**  **H Latch, Brake Pedal Return Spring - Molded**

**2** H Latch, Brake Pedal Return Spring - Material H Latch, Brake Pedal Return Spring - Material

**1 H Pin, Brake, Pivot, Main**  **H Pin, Brake, Pivot, Main**

**2 H Pin, Brake, Pivot, Machined**  **H Pin, Brake, Pivot, Machined**

**3** H Pin, Brake, Pivot, Material H Pin, Brake, Pivot, Material

**1 H Bracket, Brake Pedal**  **H Bracket, Brake Pedal**

**2 H Bracket, Brake Pedal Machined**  **H Bracket, Brake Pedal Machined**

**3 H Bracket, Brake Pedal Casting - Trimmed**  **H Bracket, Brake Pedal Casting - Trimmed**

**4 H Bracket, Brake Pedal Casting**  **H Bracket, Brake Pedal Casting**

**5** H Bracket, Brake Pedal Casting - Material H Bracket, Brake Pedal Casting - Material

1 H Pushnut, Fastener - Brake Pedal Pivot H Pushnut, Fastener

1 H Screw - Brake Pedal, Stoplight Switch Brkt H Screw - Brake Pedal, Stoplight Switch Brkt

**1 H Bracket, Brake Pedal Brakelight Switch**  **H Bracket, Brake Pedal Brakelight Switch**

**2** H Bracket, Brake Pedal Brakelight Switch Material H Bracket, Brake Pedal Brakelight Switch Material

**1 H Brake Pedal and Simulator A**  **sm H Brake Pedal and Simulator A**  **sm**
**2 H Brake Pedal A**  **rm Subassembly H Brake Pedal A**  **rm Subassembly**

**3 H Brake Pedal A**  **rm, Weldment, Painted H Brake Pedal A**  **rm, Weldment, Painted**

**4 H Brake Pedal A**  **rm, Weldment, Washed H Brake Pedal A**  **rm, Weldment, Washed**

**5 H Brake Pedal A**  **rm, Weldment, Machined H Brake Pedal A**  **rm, Weldment, Machined**

**6 H Brake Pedal, Partial Weldment, Machined**  **H Brake Pedal, Partial Weldment, Machined**

**7 H Brake Pedal A**  **rm Partial Weldment H Brake Pedal A**  **rm Partial Weldment**

**8 H Brake Pedal A**  **rm, Swaged H Brake Pedal A**  **rm, Swaged**

**9 H Brake Pedal A**  **rm Partial Weldment (stage 1) H Brake Pedal A**  **rm Partial Weldment (stage 1)**

**# H Brake Pedal A**  **rm Stamping**

**11** H Brake Pedal Arm Material

**9 H Pin, Brake Pedal Spring Pivot**  **H Pin, Brake Pedal Spring Pivot**

**# H Pin, Brake Pedal Spring Pivot - Machined** 

**11** H Pin, Brake Pedal Spring Pivot - Material

**9 H Tube, Pivot, Brake Pedal A**  **rm H Tube, Pivot, Brake Pedal A**  **rm**
**8 H Bar, Brake Pedal Spring**  **H Bar, Brake Pedal Spring**

**9 H Bar, Brake Pedal Spring - machined**  **H Bar, Brake Pedal Spring - machined**

**# H Bar, Brake Pedal Spring - cut** 

**11** H Bar, Brake Pedal Spring - bar stock

**6 H Bracket, Brake Pedal Stop**  **H Bracket, Brake Pedal Stop**

# 7 H Bracket, Brake Pedal Stop - Material H Bracket, Brake Pedal Stop - Material

**6 H Pedal Contact, Brake Pedal**  **H Pedal Contact, Brake Pedal**

**7** H Pedal Contact, Brake Pedal, Raw Material H Pedal Contact, Brake Pedal, Raw Material

3 H Bumper, Brake Pedal H Bumper, Brake Pedal

**3 H Bushing, Brake Pedal Pivot**  **H Bushing, Brake Pedal Pivot**

**3 H Contact Cover, Brake Pedal**  **H Contact Cover, Brake Pedal**

**4** H Contact Cover, Brake Pedal, Raw Material H Contact Cover, Brake Pedal, Raw Material

**2 H Simulator, Brake Pedal A**  **sm H Simulator, Brake Pedal A**  **sm**
**3 H Housing, Simlator, Brake Pedal**  **H Housing, Simlator, Brake Pedal**

**4 H Housing A** 

**sm, Brake, Simulator H Housing A**  **sm, Brake, Simulator**

**5 H Housing, Simulator, Brake - Machined**  **H Housing, Simulator, Brake - Machined**

**6 H Housing, Simulator, Brake - Casting**  **H Housing, Simulator, Brake - Casting**

**7 H Pin, Simulator - A**  **ctuator H Pin, Simulator - A**  **ctuator**

**8 H Pin, Simulator - A**  **ctuator - Washed H Pin, Simulator - A**  **ctuator - Washed**

**9 H Pin, Simulator - A**  **ctuator - Machined H Pin, Simulator - A**  **ctuator - Machined**

**#** H PIn, Simulator - Actuator - Material

7 H Housing, Simulator, Brake - Material H Housing, Simulator, Brake - Material

4 H Pin, Dowel, Split, Simulator Housing H Pin, Dowel, Split, Simulator Housing

**4 H Bushing, Brake Simulator Housing**  **H Bushing, Brake Simulator Housing**

**3 H Bumper, Leaf Spring, Simulator**  **H Bumper, Leaf Spring, Simulator**

**4** H Bumper, Leaf Spring, Simulator - Material H Bumper, Leaf Spring, Simulator - Material

**3 H Spring, Leaf, Simulator A**  **sm H Spring, Leaf, Simulator A**  **sm**
**4 H Spring, Leaf, Simulator**  **H Spring, Leaf, Simulator**

**4 H Pad #2, Leaf Spring**  **H Pad #2, Leaf Spring**

**5** H Pad #2, Leaf Spring - Material H Pad #2, Leaf Spring - Material

**4 H Pad, Spring, Leaf**  **H Pad, Spring, Leaf**

**5** H Pad, Spring, Leaf - Material H Pad, Spring, Leaf - Material

**3 H Spring, Rubber Bumper, Brake Pedal A**  **sm H Spring, Rubber Bumper, Brake Pedal A**  **sm**
**4 H Spring, Rubber Bumper, Brake Pedal - Molded**  **H Spring, Rubber Bumper, Brake Pedal - Molded**

**5** H Spring, Rubber Bumper, Brake Pedal - Material H Spring, Rubber Bumper, Brake Pedal - Material

**4 H Plate, Spring, Rubber Bumper**  **H Plate, Spring, Rubber Bumper**

**5** H Plate, Spring, Rubber Bumper, Material H Plate, Spring, Rubber Bumper, Material

**3 H Cover, Simulator, Brake Pedal**  **H Cover, Simulator, Brake Pedal**

**4 H Cover, Simulator, Brake Pedal - Washed**  **H Cover, Simulator, Brake Pedal - Washed**

**5 H Cover, Simulator, Brake Pedal - Deburred**  **H Cover, Simulator, Brake Pedal - Deburred**

**6 H Cover, Simulator, Brake Pedal - Stamped**  **H Cover, Simulator, Brake Pedal - Stamped**

**7** H Cover, Simulator, Brake Pedal - Material H Cover, Simulator, Brake Pedal - Material

3 H O-Ring, NVH, Simulator Shaft H O-Ring, NVH, Simulator Shaft

3 H Screw, Cover, Brake Pedal Spring, Primary H Screw, Cover, Simulator, Brake Pedal

0 H Screw, Brake Pedal Sensor H Screw, Brake Pedal Sensor 

# Assembly Totals

**An aly**  **zed Subs:** 78

**Unanaly zed Subs:**  17

**Parts:** 65

**Fasteners:** 19 **Parts+Unanaly**

**zed:** 82

# Design Profit ®

Copyright 2005© Munro & Associates, Inc.

# Qty **Material**

**H Bracket, Brake to Mounting Bracket** 

# 1

**H Bracket, Brake to Mounting Bracket - Stamped 1**  **Steel - 1018** H Bracket, Brake to Mounting Bracket - Material **1** Steel - 1018

H W eld Nut, Bracket, Brake 1 Commodity Pricing

H W eld Nut, Bracket, Brake 1 Commodity Pricing
H Bolt, Brake Mounting Bracket 2 Commodity Pricing
**H Brake Mounting Bracket A sm.**  **1** H Bolt, Brake Mounting Bracket **2** Commodity Pricing
**H Brake Pedal Subassembly 1** 

**H Brake Position Sensor & Brkt A sm**  **1**

**H Brake Position Sensor A sm**  **1 Commodity**  **Pricing**

**H Brake Position Sensor Bracket A sm**  **1**

**H Brake Position Sensor Bracket - Molded 1**  **PA 66 GF30** 

H Brake Position Sensor Bracket - Material **1** PA66 GF30

**H Brake Position Sensor Brkt Insert 2**  **Commodity Pricing** 

**H Brake Pedal A**

**ctuator A**

**sm 1**  **Commodity Pricing**  **H Housing, A**

**ctuator, Brake 1**  **H Housing, A**

**ctuator, Brake - Machined 1**  **H Housing, A**

**ctuator, Brake - Cut Block 1**  H Housing, Actuator, Brake - Extrusion **1** Aluminum - 7075-T6
H Ball, Stainless Steel, 3.4 mm 5 Stainless Steel - Austenitic
**H Coil, Magnetic, Brake A ctuator**  **1 Commodity**  **Pricing**
**H Piston, A**

**ctuator, Brake 2** 
**H Piston, A**

**ctuator, Washed 1** 
**H Piston, A**

**ctuator, Brake, Machined 1** 
H Piston, Actuator, Brake - Material **1** Aluminum - 6061-T6 **H O-Ring, Piston, A**

**ctuator 1**  **Commodity Pricing**  **H Spring, Coil, Piston, A ctuator, Br**  **1 Commodity**  **Pricing H Cap, Piston Spring A**  **sm 1**  **H Cap, Rim, Stamped 1**  H Cap, Rim - Material **1** Stainless Steel - 304
**H Cap, Button, Molded 1**  **Commodity Pricing**  H C-Clip, Brake Actuator Piston **1** Commodity Pricing
H Label, Brake Pedal Actuator Asm 1
H Fluid, Actuator, Brake 1
**H Plunger A**

**sm, Brake, A**

**ctuator 1** 
**H Shaft, A**

**ctuator, Brake 1** 
**H Shaft, A**

**ctuator, Brake - Machined 1** 
H Shaft, Actuator, Brake - Material **1** Stainless Steel - Austenitic
**H Bell Housing, A**

**ctuator, Brake 1**  **H Bell Housing, A**

**ctuator, Brake - Machined 1**  H Bell Housing, Actuator, Brake - Material **1** Aluminum - 6061-T6
**H Foam Wiper, A**

**ctuator, Brake 1**  **Commodity Pricing**  **H Cap, Plunger, A**

**ctuator 1**  H Cap, Plunger, Actuator - Material **1** Stainless Steel - 304
**H Stud and O-Ring A**

**sm, A ctuator**  **1**

# H Stud, Threaded, A

**ctuator, Brake 1** 
**H Stud, Threaded, A**

**ctuator, Brake - Machined 1** 
H Stud, Threaded, Actuator, Brake - Material **1** Stainless Steel - Austenitic H O-Ring, Stud, Actuator, Brake 1 Commodity Pricing
**H Retainer, Plunger, A ctuator, Brake**  **1 H Retainer, Plunger, A**  **ctuator, Brake - Machined 1**  H Retainer, Plunger, Actuator, Brake - Material **1** Stainless Steel - Austenitic

H W ire, Retaining, Plunger, Brake, Actuator 1 Stainless Steel - 304
**H Spring, Coil, A**

**ctuator, Brake 1**  **Commodity Pricing**  H Snap Ring - Actuator, Brake **1** Commodity Pricing
H Nut, Lock, Actuator, Brake 1 Commodity Pricing
**H Clevis, A**

**ctuator, Brake 1**  **Stainless Steel - A ustenitic** 
**H Clevis, A**

**ctuator, Brake, Machined 1** 
**H Clevis, A**

**ctuator, Brake - Turned 1** 
H Clevis, Actuator, Brake, Material **1** Stainless Steel - 304
**H Sensor, Pressure, Brake Pedal 1**  **Commodity Pricing** 

**2** Commodity Pricing H Clip, Spring, Brake Pedal Simulator 1 Commodity Pricing H Spring, Coil, Brake Pedal Return 1 Commodity Pricing
**H Pivot, Brake Pedal Return Spring - Molded 1**  H Pivot, Brake Pedal Return Spring - Material **1** PA66 GF30
**H Latch, Brake Pedal Return Spring - Molded 1**  H Latch, Brake Pedal Return Spring - Material **1** PBT GF20
**H Pin, Brake, Pivot, Main 1** 
**H Pin, Brake, Pivot, Machined 1** 
H Pin, Brake, Pivot, Material **1** Steel - 1018

**1**
**H Bracket, Brake Pedal Machined 1**  **H Bracket, Brake Pedal Casting - Trimmed 1**  **H Bracket, Brake Pedal Casting 1**  H Bracket, Brake Pedal Casting - Material **1** Aluminum - 332

1 Commodity Pricing H Screw - Brake Pedal, Stoplight Switch Brkt 1 Commodity Pricing
**H Bracket, Brake Pedal Brakelight Switch 1**  H Bracket, Brake Pedal Brakelight Switch Material **1** Steel - 1018

**H Brake Pedal and Simulator A sm**  **1**

**H Brake Pedal A rm Subassembly**  **1**

**H Brake Pedal A rm, Weldment, Painted**  **1**

**H Brake Pedal A rm, Weldment, Washed**  **1**

**H Brake Pedal A rm, Weldment, Machined**  **1**
**H Brake Pedal, Partial Weldment, Machined 1** 

**H Brake Pedal A rm Partial Weldment**  **1**

**H Brake Pedal A rm, Swaged**  **1**

**H Brake Pedal A rm Partial Weldment (stage 1)**  **1**

**H Brake Pedal A rm Stamping**  **1**

H Brake Pedal Arm Material **H Pin, Brake Pedal Spring Pivot 1**  **H Pin, Brake Pedal Spring Pivot - Machined 1**  H Pin, Brake Pedal Spring Pivot - Material
**H Tube, Pivot, Brake Pedal A rm**  **1 H Bar, Brake Pedal Spring**  **1 H Bar, Brake Pedal Spring - machined**  **1 H Bar, Brake Pedal Spring - cut**  **1** H Bar, Brake Pedal Spring - bar stock
**H Bracket, Brake Pedal Stop 1** 

# H Bracket, Brake Pedal Stop - Material **1** Steel - 1018
**H Pedal Contact, Brake Pedal 1**  **Steel - 1018**
H Pedal Contact, Brake Pedal, Raw Material **1** Steel - 1018
H Bumper, Brake Pedal 1 Commodity Pricing
**H Bushing, Brake Pedal Pivot 1**  **Commodity Pricing** 
**H Contact Cover, Brake Pedal 1**  **SBR**
H Contact Cover, Brake Pedal, Raw Material **1** SBR
**H Simulator, Brake Pedal A sm**  **1 H Housing, Simlator, Brake Pedal**  **1 H Housing A** 

**sm, Brake, Simulator 1**  **H Housing, Simulator, Brake - Machined 1**  **H Housing, Simulator, Brake - Casting 1** 
**H Pin, Simulator - A**

**ctuator 1** 
**H Pin, Simulator - A**

**ctuator - Washed 1** 
**H Pin, Simulator - A**

**ctuator - Machined 1** 
H PIn, Simulator - Actuator - Material **1**

H Housing, Simulator, Brake - Material 1 Aluminum - AlSi9Cu3 H Pin, Dowel, Split, Simulator Housing 2 Commodity Pricing
**H Bushing, Brake Simulator Housing 2**  **Commodity Pricing**  **H Bumper, Leaf Spring, Simulator 1**  H Bumper, Leaf Spring, Simulator - Material **1** TPE **H Spring, Leaf, Simulator A sm**  **1 H Spring, Leaf, Simulator**  **1 Commodity**  **Pricing H Pad #2, Leaf Spring**  **1** H Pad #2, Leaf Spring - Material **1** Nylon 6 **H Pad, Spring, Leaf 1**  H Pad, Spring, Leaf - Material **1** Nylon 6/6 (GF)
**H Spring, Rubber Bumper, Brake Pedal A sm**  **1 H Spring, Rubber Bumper, Brake Pedal - Molded**  **1** H Spring, Rubber Bumper, Brake Pedal - Material **1** EPDM **H Plate, Spring, Rubber Bumper 1**  H Plate, Spring, Rubber Bumper, Material **1**
**H Cover, Simulator, Brake Pedal 1** 
**H Cover, Simulator, Brake Pedal - Washed 1** 
**H Cover, Simulator, Brake Pedal - Deburred 1**  **H Cover, Simulator, Brake Pedal - Stamped 1** 
H Cover, Simulator, Brake Pedal - Material **1** Steel - 1018 H O-Ring, NVH, Simulator Shaft 3 Commodity Pricing
H Screw, Cover, Simulator, Brake Pedal 2
H Screw, Brake Pedal Sensor 2 Commodity Pricing 

# Report Totals
**Piece Cost (Total):** $29.49

**Weight (Total):** 11.2576 lb

# Page 1 of 1

# Piece Cost **Weight Piece Cost** 

**(Total)** 

# $0.68 **0.4600 lb**

**# 0.0000 lb** 
**$0.68 0.0000 lb** 

# 0.0000 lb

# 0.0000 lb $0.04 0.0263 lb
**$0.00 2.2500 lb** 
**$0.04 0.0263 lb** 
**$28.54 8.4212 lb** 

**# 0.0351 lb**  **Commodity**

**Pricing $0.00**  **0.0000 lb**
**$0.06 0.0092 lb** 
**$0.06 0.0000 lb** 
**$0.06**
**Commodity**

**Pricing $0.00**  **0.0046 lb**

**# 1.4200 lb** 
**$3.12 0.6930 lb** 
**$3.12 0.0000 lb** 
**$3.12**

Aluminum - 7075-T6 **$3.12**

Stainless Steel - Austenitic $0.00 0.0003 lb **Commodity**

**Pricing $0.00**  **0.2470 lb**
**$0.16 0.0025 lb** 
**$0.08 0.0000 lb** 
**$0.08**

Aluminum - 6061-T6 **$0.08**
**Commodity**

**Pricing $0.08**  **0.0025 lb Commodity** 

**Pricing $0.07**  **0.0194 lb**
**$0.02 0.0001 lb** 
**$0.01 0.0000 lb** 

Stainless Steel - 304 **$0.01**
**Commodity**

**Pricing $0.00**  **0.0001 lb**
**$0.00 0.0004 lb**  $0.10 0.0000 lb $0.00 0.0085 lb
**$1.77 0.0006 lb** 
**$1.05 0.0000 lb** 
**$1.05**

Stainless Steel - Austenitic **$1.05**
**$0.06 0.0000 lb** 
**$0.06**

Aluminum - 6061-T6 **$0.06**
**Commodity**

**Pricing $0.01**  **0.0001 lb**
**$0.02 0.0000 lb** 

Stainless Steel - 304 **$0.02**
**$0.64 0.0005 lb** 

# $0.36
**$0.36**

Stainless Steel - Austenitic **$0.36** Commodity Pricing $0.07
**$0.21**
**$0.21**

Stainless Steel - Austenitic **$0.21**

Stainless Steel - 304 $0.01 0.0045 lb **Commodity**

**Pricing $0.95**  **0.0345 lb**
**$0.00 0.0021 lb**  $0.00 0.0105 lb

**Stainless Steel - A ustenitic**  **$0.40 0.0749 lb** 
**$0.40 0.0000 lb** 
**$0.40**

Stainless Steel - 304 **$0.40**
**Commodity**

**Pricing $10.00**  **0.0754 lb**

**# 0.0216 lb** 

# 0.0004 lb

# 0.0313 lb

**# 0.0212 lb** 
**$0.05 0.0000 lb** 

**# 0.0237 lb** 
**$0.05 0.0000 lb** 

**# 0.3340 lb** 
**$0.31 0.0000 lb** 
**$0.31 0.0000 lb** 

**# 1.9350 lb** 
**$2.52 0.0000 lb** 
**$2.52 0.0000 lb** 
**$2.52**

Aluminum - 332 **$2.52**

# 0.0000 lb

# 0.0099 lb

**# 0.0000 lb** 
**$0.13 0.0000 lb** 

**# 4.5374 lb** 
**$6.56 3.1024 lb** 
**$5.98 0.8071 lb** 
**$5.98**
**$5.98**
**$5.66**
**$5.66**
**$5.52**
**$5.10**

**1** Steel - 1018

**Stainless Steel - A ustenitic**  **$0.42**

**1** Stainless Steel - 416 Bar Stock
**Commodity**

**Pricing $0.00** 
**$0.14**
**$0.14**

**1** Steel - 1018
**$0.13**

# Steel - 1018 **$0.13**

**Steel - 1018 $0.19** 

Steel - 1018 **$0.19** Commodity Pricing $0.01 0.0033 lb **Commodity**

**Pricing $0.38**  **0.0234 lb**
**$0.19 0.1557 lb** 
**$0.19**
**$1.88 1.3715 lb** 
**$1.43 0.9956 lb** 
**$1.09**
**$1.09**
**$1.09**
**$0.04**
**$0.04**
**$0.04**

Steel - 1018

Aluminum - AlSi9Cu3 $1.05
Commodity Pricing $0.03
**Commodity**

**Pricing $0.14** 
**$0.01 0.0004 lb** 
**$0.01**
**$0.10 0.1155 lb**  **Commodity**

**Pricing $0.00** 
**$0.00**
**$0.00**
**$0.10** Nylon 6/6 (GF) **$0.10**
**$0.13 0.0595 lb** 
**$0.12**
**$0.12**
**$0.01**
**$0.01**
**$0.21 0.1790 lb** 
**$0.21**
**$0.21**
**$0.21**

Steel - 1018 **$0.21** Commodity Pricing $0.00 0.0001 lb $0.00 0.0106 lb $0.06 0.0106 lb 

# Preassembled Totals

**Analyzed Subs:** 0

**Unanalyzed Subs:** 0

**Parts:** 0

**Fasteners:** 0 **Parts+Unanalyzed:** 0

# Piece Cost **Weight (Total)**

**(Total)** 

# $0.68 **0.4600 lb**

**$0.68 0.0000 lb** 

**$0.68 0.0000 lb**  $0.00 0.0000 lb $0.00 0.0000 lb $0.08 0.0526 lb
**$0.00 2.2500 lb** 
**$0.08 0.0526 lb** 
**$28.54 8.4212 lb** 

**$0.06 0.0351 lb** 

**$0.00 0.0000 lb** 
**$0.06 0.0092 lb** 

**0.0000 lb $0.06**  **0.0000 lb**

**0.0000 lb $0.06**  **0.0000 lb**

**0.0046 lb $0.00**  **0.0092 lb**
**$16.75 1.4200 lb** 

**$3.12 0.6930 lb** 

**0.0000 lb $3.12**  **0.0000 lb**

**0.0000 lb $3.12**  **0.0000 lb**

**0.0000 lb $3.12**  **0.0000 lb** $0.00 0.0015 lb
**$0.00 0.2470 lb** 
**$0.31 0.0050 lb** 

**0.0000 lb $0.16**  **0.0000 lb**

**0.0000 lb $0.16**  **0.0000 lb**

**0.0000 lb $0.16**  **0.0000 lb**

**0.0025 lb $0.15**  **0.0050 lb**
**$0.07 0.0194 lb** 
**$0.02 0.0001 lb** 

**0.0000 lb $0.01**  **0.0000 lb**

**0.0000 lb $0.01**  **0.0000 lb**

**0.0001 lb $0.00**  **0.0001 lb**
**$0.00 0.0004 lb**  $0.10 0.0000 lb $0.00 0.0085 lb
**$1.77 0.0006 lb** 

**0.0000 lb $1.05**  **0.0000 lb**

**0.0000 lb $1.05**  **0.0000 lb**

**0.0000 lb $1.05**  **0.0000 lb**

**0.0000 lb $0.06**  **0.0000 lb**

**0.0000 lb $0.06**  **0.0000 lb**

**0.0000 lb $0.06**  **0.0000 lb**

**0.0001 lb $0.01**  **0.0001 lb**

**0.0000 lb $0.02**  **0.0000 lb**

**0.0000 lb $0.02**  **0.0000 lb**

**0.0005 lb $0.64**  **0.0005 lb**

# 0.0000 lb **$0.36 0.0000 lb** 

**0.0000 lb $0.36**  **0.0000 lb**

**0.0000 lb $0.36**  **0.0000 lb**

0.0005 lb $0.07 0.0005 lb

**0.0000 lb $0.21**  **0.0000 lb**

**0.0000 lb $0.21**  **0.0000 lb**

**0.0000 lb $0.21**  **0.0000 lb** $0.01 0.0045 lb
**$0.95 0.0345 lb** 
**$0.00 0.0021 lb**  $0.00 0.0105 lb
**$0.40 0.0749 lb** 

**0.0000 lb $0.40**  **0.0000 lb**

**0.0000 lb $0.40**  **0.0000 lb**

**0.0000 lb $0.40**  **0.0000 lb**
**$10.00 0.0754 lb** 
**$0.15 0.0432 lb**  $0.00 0.0004 lb $0.07 0.0313 lb
**$0.05 0.0212 lb** 

**$0.05 0.0000 lb** 
**$0.05 0.0237 lb** 

**$0.05 0.0000 lb** 
**$0.31 0.3340 lb** 

**$0.31 0.0000 lb** 

**0.0000 lb $0.31**  **0.0000 lb**
**$2.52 1.9350 lb** 

**$2.52 0.0000 lb** 

**0.0000 lb $2.52**  **0.0000 lb**

**0.0000 lb $2.52**  **0.0000 lb**

**0.0000 lb $2.52**  **0.0000 lb** $0.01 0.0000 lb $0.01 0.0099 lb
**$0.13 0.0000 lb** 

**$0.13 0.0000 lb** 
**$8.44 4.5374 lb** 

**$6.56 3.1024 lb** 

**0.8071 lb $5.98**  **0.8071 lb**

**0.8071 lb $5.98**  **0.8071 lb**

**0.8071 lb $5.98**  **0.8071 lb**

**0.4440 lb $5.66**  **0.4440 lb**

**0.4440 lb $5.66**  **0.4440 lb**

**0.1940 lb $5.52**  **0.1940 lb**

**0.0000 lb $5.10**  **0.0000 lb**

**$5.10 0.0000 lb**  **$5.10 0.0000 lb** 
**$5.10 0.0000 lb**  **# 0.0000 lb** 

**0.0440 lb $0.42**  **0.0440 lb**
**$0.42 0.0000 lb**  **$0.42 0.0000 lb** 
**$0.42 0.0000 lb**  **# 0.0000 lb** 

**0.1500 lb $0.00**  **0.1500 lb**

**0.2500 lb $0.14**  **0.2500 lb**

**0.2500 lb $0.14**  **0.2500 lb**
**$0.14 0.2500 lb**  **$0.14 0.2500 lb** 
**$0.14 0.0000 lb**  **# 0.0000 lb** 

**0.0000 lb $0.13**  **0.0000 lb**

# 0.0000 lb **$0.13 0.0000 lb** 

**0.3631 lb $0.19**  **0.3631 lb**

**0.3631 lb $0.19**  **0.3631 lb**

0.0033 lb $0.01 0.0033 lb

**0.0234 lb $0.38**  **0.0234 lb**

**0.1557 lb $0.19**  **0.1557 lb**

**0.1557 lb $0.19**  **0.1557 lb**
**$1.88 1.3715 lb** 

**0.9956 lb $1.43**  **0.9956 lb**

**0.9800 lb $1.09**  **0.9800 lb**

**0.9800 lb $1.09**  **0.9800 lb**

**0.9800 lb $1.09**  **0.9800 lb**

**0.0000 lb $0.04**  **0.0000 lb**

**0.0000 lb $0.04**  **0.0000 lb**

**0.0000 lb $0.04**  **0.0000 lb**
**$0.04 0.0000 lb**  **$0.04 0.0000 lb** 

0.0000 lb $1.05 0.0000 lb

0.0000 lb $0.06 0.0000 lb

**0.0078 lb $0.28**  **0.0156 lb**

**0.0004 lb $0.01**  **0.0004 lb**

**0.0000 lb $0.01**  **0.0000 lb**

**0.1155 lb $0.10**  **0.1155 lb**

**0.1155 lb $0.00**  **0.1155 lb**

**0.0000 lb $0.00**  **0.0000 lb**

**0.0000 lb $0.00**  **0.0000 lb**

**0.0000 lb $0.10**  **0.0000 lb**

**0.0000 lb $0.10**  **0.0000 lb**

**0.0595 lb $0.13**  **0.0595 lb**

**0.0539 lb $0.12**  **0.0539 lb**

**0.0000 lb $0.12**  **0.0000 lb**

**0.0056 lb $0.01**  **0.0056 lb**

**0.0000 lb $0.01**  **0.0000 lb**

**0.1790 lb $0.21**  **0.1790 lb**

**0.0000 lb $0.21**  **0.0000 lb**

**0.0000 lb $0.21**  **0.0000 lb**

**0.0000 lb $0.21**  **0.0000 lb**

**0.0000 lb $0.21**  **0.0000 lb**

0.0001 lb $0.00 0.0003 lb

0.0106 lb $0.00 0.0212 lb $0.12 0.0212 lb

# Shippied into OEM as a Brake Pedal Assembly

Assume Tier 2 shipped as an assembly to T1/OEM

Includes Tier1I/OEM markup Used: **T1 Moderate Assembly Complexity**

Assumed returnable dunnage - no dividers Used: **Returnable Dunnage**

Housing, Actuator, Brake Machined "See red tab for cast estimate"

Brake pedal Brakelight Switch - Used 0.55/lb per material spec of MC-Steel-1000s, Coil Lean Design used ~$1.08/lb (See Brake Pedal Subassembly tab) Pin - Brake Pedal Spring Pivot - Used $1.41/lb per material spec of S-Steel-416, Bar Lean Design used ~$3.00/lb ( See Brake Peadl Arm, Weldment tab)

# Brake pedal Brakelight Switch - Used 0.55/lb per material spec of MC-Steel-1000s, Coil Lean Design used ~$1.08/lb (See Brake Pedal Subassembly tab) Pin - Brake Pedal Spring Pivot - Used $1.41/lb per material spec of S-Steel-416, Bar Lean Design used ~$3.00/lb ( See Brake Peadl Arm, Weldment tab)

# 0



# 060600 Brake A **ctivation Subsy stem** 

1 **00**

A Assembly

of Brake Activation Subsy stem Components

2 **01**

A H Master Cy linder

3 **02**

A H Brake Pedal Assembly 06 06 02

- N0502

- 01



# NEW TECHNOLOGY GENERA **L PA RT INFORMA**  **TION: 2010 Ford Fusion, 2.5L A**  **tkinson Cy cle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery**

**275V, Nominal Pack Capacity 5.5A**  **h, 1.51kWh)**SubassemblyComponent



# Name/Description Part NumberItemSubsystemSub-SubsystemAssembly



# As **sembly of Brake A ctivation Subsystem** 

**Ma ster Cylinder and Reservoir** 

**Pedals** 

# Technology **Level: Parallel HEV Technology**

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4**

**- 6 Passengers**  **Study Case#: N0502 (N=New, B=Base, ) 05=Technology**  **Package, 02=Vehicle Class**

A H Brake Pedal Assembly 06 06 02

- N0502

- 01

4 **03**

A Brake Line Assembly #1- HCU to Control valve

B Brake Line Assembly #2- HCU to Control valve

5 **05**

A Brake Pressure Control Valve

6 **06**

7 **10**

8 **60**

A Wi re Harness - Solenoid, Brake Pedal Cut-off Value (XX Pins)

B Wi re Harness - Pressure Sensor, Brake Pedal Cutt-off Valve (XX Pins)

C

D Wi re Harness - Brakelamp/Redundant Cruise Deact (4 Pins) **Brake Fluid Brake Lines and Hoses** 

**Brake Control Valve**

**TBD**

**Wire Harness Connections**

Wi re Harness - Angle Sensor, Brake Pedal & Bracket Assembly

(XX Pins)

# 9 **70**

A H Vacuum Hose Assembly , Booster

10 **75**

A Bracket - Brake Pedal

11 **80**

A Nut - Pedal & Bracket Assembly Brake to Booster

B Bolt - Pedal & Bracket Assembly Brake to Int.Cowl Brkt

C Bolt - Cowl Int. Brkt to Cowl Brkt. (Same as B)

12 **85**

13 **90**

14 **99**

A Switch - Brake Lamp and Redundant Cruise Deact

B Pin - Booster Clevis

C Clip - Pin, Booster Clevis **Pipes, Hoses, Ducting**

**Sealing Elements Brackets** 

**Boltings**

**Bearings Elements Misc**

**Miscellaneous**

**NOTES:**



# 1. **= A**

**highlighted Sub-subsystem, A ssembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**  **the competing technology**

# Material Labor Burden

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

#REF! #REF! #REF!



# #REF! #REF! #REF! 

# NEW TECHNOLOGY PA **CKA GE QUOTE** 

**PA RA**  **METERS**QTY/Subsystem 

# Full, Modification, Differential,
or Not Applicable
Quote Level Scaling

Factor (Default =1) Notes Manufacturing 

# 6 Passengers **Study Case#: N0502 (N=New, B=Base, ) 05=Technology**  **Package, 02=Vehicle Class**

#REF! #REF! #REF!

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#REF! #REF! #REF!

**= A**

**highlighted Sub-subsystem, A ssembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of** 

# End Item Scrap SG&A Profit ED&T-R&D

**- $** 

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# NEW TECHNOLOGY PA **CKA GE COST INFORMA**  **TION**

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**Cost (Component/**  **Assembly )**  **Total**

**Packaging**

**Cost (Component**  **/ Assembly )**  **Net**

**Component/ Assembly**  **Cost Impact to**

**OEM Total**  **Manufacturing**

**Cost (Component/**  **Assembly )** 



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