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 Actuation Subsystem

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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

SUBSYSTEM ROLL-UP $ 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

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 TECHNOLOG

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 INFORMATION

Item

Subsystem

Sub-Subsystem

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

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

(x1000) (Component/ 

Assembly) Assembly) (Component/ Assembly)

Cost Impact to 

OEM

(Component/ 

Assembly)

Subsystem

Sub-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: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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SU

BS

YS

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

INCREMENTAL COST TO U

Manufacturing Total 

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Subsystem

Sub-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 Cylinder 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)

Item

Subsystem

Sub-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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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 Actuation Subsystem

1 00

2 01

3 02

4 03

5 05

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

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) $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ 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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 2.60 $ 1.82 $ 0.78 $ 5.19 $ 0.03 $ 0.34 $ 0.31 $ 0.13 $ 0.81 $ 0.06 $ 6.06 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.78 $ 0.07 $ 0.55 $ 1.40 $ 0.00 $ 0.08 $ 0.06 $ 0.01 $ 0.16 $ 0.01 $ 1.56 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ 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 DESCRIPTION

Item

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

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 DESCRIPTION

Item

Subsystem

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-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 Cylinder 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

Subsystem

Sub-Subsystem

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Assembly) (Component

/ Assembly)

Cost Impact to 

OEM

(x1000)

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: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 DESCRIPTION

Item

Subsystem

M1 99

2

N1 00

2

SU

BS

YS

TECHNO

LOGY 

PACKAG

Subsystem

Sub-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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup

Total Markup Total Net 

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

Item

Subsystem

Sub-Subsystem

End Item 

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

$ - $ - $ - $ - $ - $ - $ 1.71 $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ 0.07 $ 0.95 $ 0.85 $ 0.33 $ 2.20 $ 0.10 $ 15.55 $ - $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ -

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 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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 DESCRIPTION

Item

Subsystem

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

#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 Actuation Subsystem

1 00

2 01

3 02

4 03

5 05

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

$ -

$ -

$ -

$ -

$ -

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 DESCRIPTION

Item

Subsystem

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 DESCRIPTION

Item

Subsystem

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

Investment(X1

000)

05 Cylinder 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

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

M1 99

2

N1 00

2

SU

BS

YS

TECHNO

LOGY 

PACKAG

Subsystem

Sub-Subsystem

Investment(X1

000)

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

Item

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

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 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

060600 Brake Actuation Subsystem

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 INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

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&D

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

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&D

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

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 Actuation Subsystem

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 Number

QTY/ Subsystem

Notes

Subassembly

Component

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)

Item

Subsystem

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

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

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)

Item

Subsystem

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

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

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)

Item

Subsystem

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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 SubFile: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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

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 a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

PACKAGING 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 (Weeks/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 Weekly Component Volume: Packaging Specification: n/a

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Packaging 

Cost per 

Piece

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.41 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

B

C

D

E

F

G

H

I

J

K

L

M

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

M $0.00

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

B

C

D

E

F

G

H

I

J

K

L

M

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 Assembly 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 Weld Nut, Bracket, Brake 06 06 02 - N0502- 06

H Weld Nut, Bracket, Brake 06 06 02 - N0502- 07

Name/Description Part Number

NEW TECHNOLOGY GENERAL PART INFORMATION:

 2010 Ford Fusion 2.5L Atkinson Cycle, I4 156hp (191 Net) Mild HEV 

(Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51 

kWh)

Item

Subsystem

Sub-Subsystem

Assembly

Subassembly

Component

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=V

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 Asm. 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 Asm 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 Actuator Asm 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 Wire, Retaining, Plunger, Brake, Actuator 06 06 02 - N0502- 38

H Sensor, Pressure, Brake Pedal 06 06 02 - N0502- 39

C3 H Piston, Actuator, Brake 06 06 02 - N0502- 40

H Piston, Actuator, Washed 06 06 02 - N0502- 41

H O-Ring, Piston, Actuator 06 06 02 - N0502- 42

C4 H Cap, Piston Spring Asm 06 06 02 - N0502- 43

H Cap, Rim 06 06 02 - N0502- 44

H Cap, Button 06 06 02 - N0502- 45

C5 H Plunger Asm, Brake, Actuator 06 06 02 - N0502- 46

H Shaft, Actuator, Brake 06 06 02 - N0502- 47

H Bell Housing, Actuator, Brake H Bell Housing, Actuator, Brake 06 06 02 - N0502- 48

H Foam Wiper, Actuator, Brake 06 06 02 - N0502- 49

H Cap, Plunger, Actuator 06 06 02 - N0502- 50

C5A H Stud and O-Ring Asm, Actuator 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 Asm 06 06 02 - N0502- 55

C6A H Brake Pedal Arm 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 Arm, Weldment, Painted 06 06 02 - N0502- 60

H Brake Pedal Arm, Partial Weldment 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 Asm 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 Asm 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 Asm. 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 Asm., 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, Assembly or Component row indicates design and/or manufacturing diffe

the competing technology
Material Labor Burden

$ - $ - $ -

$ - $ - $ -

1 $ - $ - $ -

2 PIA

2 PIA

2 PIA

1 $ - $ - $ -

1 PIA

1 PIA

Manufacturing 

Q

T

Y/ Subsyste

m

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Notes

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

6 Passengers

ology 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 Subsystem Quote 

(Yes/No)

/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 PACKAGE COST INFORMATION

$ 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)

System 

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 Weld Nut, Bracket, Brake 060602-N0502-06 1 S $0.00 $0.05 $0.00 $0.05 $0.05

3 H Weld 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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

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

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

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

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

File: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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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 Weld Nut, Bracket, Brake 060602-N0502-06

H Weld 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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 Weld Nut, Bracket, Brake 060602-N0502-06

H Weld 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.223 $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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations. 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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

a) Items 1,2, & 3 must a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

$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 a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 SubAssembly.

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

3

1

Notes: 

a) Items 1,2, & 3 must a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

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

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

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

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

File: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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 SubAssembly.

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

3

1

Notes: 

a) Items 1,2, & 3 must a

(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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

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

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

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

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

File: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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 Wiper, 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 SubAssembly.

"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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

PACKAGING 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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 Wiper, 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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 Wiper, 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 SubAssembly.

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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

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

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

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

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

File: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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 SubAssembly.

3

1

Notes: 

a) Items 1,2, & 3 must a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

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

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

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

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

File: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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

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

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

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

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

File: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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 Weldment

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 Weldment

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 Weldment

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 Weldment 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 Weldment

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 Weldment

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 Weldment 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 Weldment 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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 SubAssembly.

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

3

1

Notes: 

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

a) Items 1,2, & 3 must a

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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 Weldment

060602-N0502-61

H Brake Pedal Arm, Partial Weldment

060602-N0502-61A

H Brake Pedal Arm, Partial Weldment

060602-N0502-61B

H Brake Pedal Arm, Partial Weldment 060602-N0502-61C

H Brake Pedal Arm, Partial Weldment

060602-N0502-61D

H Brake Pedal Arm, Partial Weldment

060602-N0502-61E

H Brake Pedal Arm, Partial Weldment 060602-N0502-61F

H Brake Pedal Arm, Partial Weldment 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

H Tube, Pivot, Brake Pedal Arm 060602-N0502-63

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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 Weldment

060602-N0502-61

H Brake Pedal Arm, Partial Weldment

060602-N0502-61A

H Brake Pedal Arm, Partial Weldment

060602-N0502-61B

H Brake Pedal Arm, Partial Weldment 060602-N0502-61C

H Brake Pedal Arm, Partial Weldment

060602-N0502-61D

H Brake Pedal Arm, Partial Weldment

060602-N0502-61E

H Brake Pedal Arm, Partial Weldment 060602-N0502-61F

H Brake Pedal Arm, Partial Weldment 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

H Tube, Pivot, Brake Pedal Arm 060602-N0502-63

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 SubAssembly.

3 H O-Ring, NVH, Simulator Shaft 060602-N0502-71 3 S "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to $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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

(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 

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

H O-Ring, NVH, Simulator Shaft 060602-N0502-71 $0.02

$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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 Sub2 Assembly. 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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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 

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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 RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 SubAssembly.

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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

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

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

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

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

File: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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 Sub2 H Bushing, Brake Simulator Housing Assembly. 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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

a) Items 1,2, & 3 must a

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

H Bushing, Brake Simulator Housing 060602-N0502-82 $0.28

$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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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 In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 SubAssembly.

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

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 a

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 (Weeks/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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

$0.03 $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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H Housing , Actuator, Brake 060602-N0502-27 360 10.00 0.25

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 Assembly Part # QTY $$$ Comments

H Brake Pedal Assembly 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 Weld Nut, Bracket, Brake 1 0.06

H Weld Nut, Bracket, Brake 1 0.06

B H Brake Mounting Bracket Asm. 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 Asm 1 0.21

H Brake Position Sensor Asm 1 5.81 Commodity pricing

C1A H Brake Position Sensor Bracket Asm 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 Actuator Asm 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 Wire, Retaining, Plunger, Brake, Actuator 1 0.01

H Sensor, Pressure, Brake Pedal 1 11.55 Commodity pricing

C3 H Piston, Actuator, Brake 2 0.30

H Piston, Actuator, Washed 2 1.60

H O-Ring, Piston, Actuator 2 0.19 Commodity pricing

C4 H Cap, Piston Spring Asm 1 0.09

H Cap, Rim 1 0.05

H Cap, Button 1 0.04

C5 H Plunger Asm, Brake, Actuator 1 0.11

H Shaft, Actuator, Brake 1 3.42
H Bell Housing, Actuator, Brake 1 0.91

H Foam Wiper, Actuator, Brake 1 0.01 Commodity pricing

H Cap, Plunger, Actuator 1 0.03

C5A H Stud and O-Ring Asm, Actuator 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 Asm 1 0.13 Push Together

C6A H Brake Pedal Arm 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 Arm, Weldment, Painted 1 0.19

H Brake Pedal Arm, Partial Weldment 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 Asm 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 Asm 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

H Plate, Spring, Rubber Bumper 1 0.01

C6B3 H Housing Asm., 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

Commodity pricing

Commodity pricing

Commodity pricing

Commodity pricing?

Commodity pricing?

Commodity pricing?

Commodity pricing

Commodity pricing?

Commodity pricing

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

Commodity pricing

Commodity pricing?

Commodity pricing

Bumper and plate held together w/o adhesive

Commodity pricing

Commodity pricing
Assembly Report

H Brake Pedal Assembly

Labor Type Parent Name Symbol 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 Weld Auto Load

$44.96 Tool H Bracket, Brake to Mounting Bracket Projection Welder

- - - 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 - StampedStamping 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

- - - Weld nuts (2)

$44.96 Part H Bracket, Brake to Mounting Bracket H Weld Nut, Bracket, Brake

$44.96 Fastening H Bracket, Brake to Mounting Bracket Projection Weld

$44.96 Operation H Bracket, Brake to Mounting Bracket CDI

$44.96 Part H Bracket, Brake to Mounting Bracket H Weld Nut, Bracket, Brake

$44.96 Fastening H Bracket, Brake to Mounting Bracket Projection Weld

- - - 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 Washer Med Batch special nozzels

- - - "Washing, 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 Washer

- - - medium batch/individual with special spray nozzels

$49.29 Operation H Housing, Actuator, Brake Load Part

$49.29 Operation H Housing, Actuator, Brake Wash 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, Washed

- - - "Washing, Small Size and/or Low Complexity"

$35.51 Tool H Piston, Actuator, Washed Washer Duo 400 Wash Rinse & DRY

- - - Batch Type Washer

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2

$28.18 P.-P. Part H Piston, Actuator, Washed 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, Washed Load Part

$35.51 Operation H Piston, Actuator, Washed Wash Part Medium

$35.51 Operation H Piston, Actuator, Washed 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 Assembly

Labor Type Parent Name Symbol 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

- - - "Washing, Small Size and/or Low Complexity"

$35.51 Tool H Shaft, Actuator, Brake Washer Duo 400 Wash Rinse & DRY

- - - Batch Type Washer

- - - 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 Wash 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

- - - "Washing, Small Size and/or Low Complexity"

$20.81 Tool H Bell Housing, Actuator, Brake Washer Duo 400 Wash Rinse & DRY

- - - Batch Type Washer

- - - 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 Wash Part Medium

$20.81 Operation H Bell Housing, Actuator, Brake Unload Part

$35.51 P.-P. Part H Plunger Asm, Brake, Actuator H Foam Wiper, 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 Wire, 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

- - - Space for Printing

- - - Space for Printing

Design Profit ®

Page 2 of 6

Copyright 2005© Munro & Associates, Inc.

H Brake Pedal Assembly

Labor Type Parent Name Symbol Name

Rate

- - - 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

$10.75 P.-P. Part H Brake Pedal Actuator Asm H Clevis, Actuator, Brake

- - - "Washing, Small Size and/or Low Complexity"

$10.75 Tool H Clevis, Actuator, Brake Washer Duo 400 Wash Rinse & DRY
- - - Batch Type Washer

- - - 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 Wash 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

- - - Space for Printing

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$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

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

- - - Space for Printing

$10.75 P.-P. Part H Brake Pedal Subassembly H Pin, Brake, Pivot, Main

- - - "Washing, Small Size and/or Low Complexity"

$10.75 Tool H Pin, Brake, Pivot, Main Washer Duo 400 Wash 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 Washer

- - - 5-10 min cycle time

Design Profit ®

Page 3 of 6

Copyright 2005© Munro & Associates, Inc.

H Brake Pedal Assembly

Labor Type Parent Name Symbol 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 Wash 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 

- - - "Washing, Medium Size and/or Moderate Complexity"

$49.29 Tool H Bracket, Brake Pedal Washer Med Batch special nozzels

- - - In-Line Washer

- - - 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 Wash 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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$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

- - - Space for Printing

- - - 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, Weldment, Painted

$55.17 Tool H Brake Pedal Arm, Weldment, Painted Paint Line

- - - Paint line - dipped in liquid paint - air dried

$55.17 Operation H Brake Pedal Arm, Weldment, Painted Load Part

$20.81 Subassembly H Brake Pedal Arm, Weldment, Painted H Brake Pedal Arm, Weldment, Washed

$20.81 Tool H Brake Pedal Arm, Weldment, Washed Washer Turbo Tunnel 

- - - In-Line Washer

$44.96 Subassembly H Brake Pedal Arm, Weldment, Washed H Brake Pedal Arm, Weldment, Machined

$44.96 Tool H Brake Pedal Arm, Weldment, Machined Projection Welder

- - - Final Welding

$44.96 Operation H Brake Pedal Arm, Weldment, Machined Clamp Part

##### Subassembly H Brake Pedal Arm, Weldment, Machined H Brake Pedal, Partial Weldment, Machined

##### Tool H Brake Pedal, Partial Weldment, Machined EC-400-ML Horizontal CNC Machine

$44.96 Subassembly H Brake Pedal, Partial Weldment, Machined H Brake Pedal Arm Partial Weldment
$44.96 Tool H Brake Pedal Arm Partial Weldment Projection Welder

- - - Initial Welding

$42.18 Subassembly H Brake Pedal Arm Partial Weldment 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 Weldment (stage 1)

$35.42 Tool H Brake Pedal Arm Partial Weldment (stage 1) EC-400-ML Horizontal CNC Machine

- - - Initial machining - holes in pedal arm

$42.91 P.-P. Part H Brake Pedal Arm Partial Weldment (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 Weldment (stage 1) Load Part

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) Clamp Part

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Bore Hole 1-30mm

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) CDI

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Bore Hole 1-30mm

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) CDI

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Bore Hole 1-30mm

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) CDI

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Bore Hole 1-30mm

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) Change Tool

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Cut slot

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) CDI

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Cut slot

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) Change Tool

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Chamfer Edge

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) CDI

$35.42 Material Mod. H Brake Pedal Arm Partial Weldment (stage 1) Chamfer Edge

$35.42 Operation H Brake Pedal Arm Partial Weldment (stage 1) Unclamp Part

$35.42 Operation H Brake Pedal Arm Partial Weldment (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 Washer Duo 400 Wash 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 Washer

- - - 5-10 min cycle time

Design Profit ®

Page 4 of 6

Copyright 2005© Munro & Associates, Inc.
H Brake Pedal Assembly

Labor Type Parent Name Symbol 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 Wash 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 Weldment Clamp Part

- - - 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 P.-P. Part H Brake Pedal Arm Partial Weldment H Bar, Brake Pedal Spring

$35.51 Tool H Bar, Brake Pedal Spring Washer Duo 400 Wash Rinse & DRY

- - - Wash

$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 Washer

- - - 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 Wash Part Medium

$35.51 Operation H Bar, Brake Pedal Spring Unload Part

$44.96 Fastening H Brake Pedal Arm Partial Weldment Seam Weld 

$44.96 Operation H Brake Pedal Arm Partial Weldment CDI

$44.96 Fastening H Brake Pedal Arm Partial Weldment Seam Weld 

$44.96 Operation H Brake Pedal Arm Partial Weldment Unclamp Part

- - - Final machining

##### Operation H Brake Pedal, Partial Weldment, Machined Load Part

##### Operation H Brake Pedal, Partial Weldment, Machined Clamp Part
- - - Cut pivot to length

##### Material Mod. H Brake Pedal, Partial Weldment, Machined Cut to Length

##### Operation H Brake Pedal, Partial Weldment, Machined Change Tool

##### Material Mod. H Brake Pedal, Partial Weldment, Machined Chamfer ID

##### Operation H Brake Pedal, Partial Weldment, Machined Part Manipulation

##### Material Mod. H Brake Pedal, Partial Weldment, Machined Chamfer OD sml

##### Operation H Brake Pedal, Partial Weldment, Machined Change Tool

##### Material Mod. H Brake Pedal, Partial Weldment, Machined Milled face

##### Operation H Brake Pedal, Partial Weldment, Machined CDI

##### Material Mod. H Brake Pedal, Partial Weldment, Machined Milled face

##### Operation H Brake Pedal, Partial Weldment, Machined CDI

##### Material Mod. H Brake Pedal, Partial Weldment, Machined Milled face

##### Operation H Brake Pedal, Partial Weldment, Machined CDI

##### Material Mod. H Brake Pedal, Partial Weldment, Machined Milled face

##### Operation H Brake Pedal, Partial Weldment, Machined Unclamp Part

$44.96 Operation H Brake Pedal Arm, Weldment, Machined Clamp Part

$44.96 P.-P. Part H Brake Pedal Arm, Weldment, 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, Weldment, Machined Seam Weld 

$44.96 Operation H Brake Pedal Arm, Weldment, Machined CDI

$44.96 Fastening H Brake Pedal Arm, Weldment, Machined Seam Weld 

$44.96 Operation H Brake Pedal Arm, Weldment, Machined Clamp Part

$15.50 P.-P. Part H Brake Pedal Arm, Weldment, 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, Weldment, Machined Seam Weld 

$44.96 Operation H Brake Pedal Arm, Weldment, Machined CDI

$44.96 Fastening H Brake Pedal Arm, Weldment, Machined Seam Weld 

$44.96 Operation H Brake Pedal Arm, Weldment, Machined Unclamp Part

$20.81 Operation H Brake Pedal Arm, Weldment, Washed Load Part

$20.81 Operation H Brake Pedal Arm, Weldment, Washed Wash Part Medium

$20.81 Operation H Brake Pedal Arm, Weldment, Washed Unload Part

$55.17 Operation H Brake Pedal Arm, Weldment, 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

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- - - 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

- - - Washed machined housing

$20.81 Subassembly H Housing, Simlator, Brake Pedal H Housing Asm, Brake, Simulator

- - - "Washing, Small Size and/or Low Complexity"

$20.81 Tool H Housing Asm, Brake, Simulator Washer Duo 400 Wash Rinse & DRY

- - - Batch Type Washer

- - - 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 - Washed

- - - "Washing, Small Size and/or Low Complexity"

$10.75 Tool H Pin, Simulator - Actuator - Washed Washer Duo 400 Wash Rinse & DRY

- - - Batch Type Washer

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2

$20.90 P.-P. Part H Pin, Simulator - Actuator - Washed 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 - Washed Load Part

$10.75 Operation H Pin, Simulator - Actuator - Washed Wash Part Medium

$10.75 Operation H Pin, Simulator - Actuator - Washed 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 Assembly

Labor Type Parent Name Symbol 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 Wash 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 - Washed

- - - "Washing, Small Size and/or Low Complexity"

$55.17 Tool H Cover, Simulator, Brake Pedal - Washed Washer Duo 400 Wash Rinse & DRY

- - - Batch Type Washer

$55.17 P.-P. Part H Cover, Simulator, Brake Pedal - Washed 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 - Washed Load Part

$55.17 Operation H Cover, Simulator, Brake Pedal - Washed Wash Part Medium

$55.17 Operation H Cover, Simulator, Brake Pedal - Washed 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 of6

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 Weld 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 Weld 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

- $0.031

0.0000 sec 0.0000 sec $0.00 $0.001

--

-

---

H Housing, Actuator, Brake - Machined 3.0000 sec 3.0000 sec- $0.041

--

-

---

0.0000 sec 0.0000 sec $0.00 $0.001

H Housing, Actuator, Brake - Cut Block 12.0000 sec 12.0000 sec- $0.201

0.0000 sec 0.0000 sec $0.00 $0.001

H Housing, Actuator, Brake - Extrusion 0.0000 sec 0.0000 sec $3.12 $0.001

4.0000 sec 4.0000 sec $0.00 $0.031

--

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---

--

-

---

3.0000 sec 3.0000 sec $0.00 $0.051

3.0000 sec 3.0000 sec $0.00 $0.051

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

1.0000 sec 1.0000 sec $0.00 $0.021

3.0000 sec 3.0000 sec $0.00 $0.051

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

3.0000 sec 3.0000 sec $0.00 $0.051

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

2.5000 sec 2.5000 sec $0.00 $0.041

3.0000 sec 3.0000 sec $0.00 $0.051

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031
2.0000 sec 2.0000 sec $0.00 $0.03

1

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

3.0000 sec 3.0000 sec $0.00 $0.051

1.0000 sec 1.0000 sec $0.00 $0.021

2.0000 sec 2.0000 sec $0.00 $0.031

2.5000 sec 2.5000 sec $0.00 $0.041

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

0.0000 sec 0.0000 sec $0.00 $0.001

3.0000 sec 3.0000 sec $0.00 $0.051

3.0000 sec 3.0000 sec $0.00 $0.051

2.0000 sec 2.0000 sec $0.00 $0.031

1.0000 sec 1.0000 sec $0.00 $0.021

0.0000 sec 0.0000 sec $0.00 $0.001

3.0000 sec 3.0000 sec $0.00 $0.051

3.0000 sec 3.0000 sec $0.00 $0.051

5.0000 sec 5.0000 sec $0.00 $0.081

1.0000 sec 1.0000 sec $0.00 $0.021

--

-

---

--

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---

3.0000 sec 3.0000 sec $0.00 $0.041

5.0000 sec 5.0000 sec $0.00 $0.071

2.0000 sec 2.0000 sec $0.00 $0.031

0.0000 sec 0.0000 sec $0.00 $0.001

H Ball, Stainless Steel, 3.4 mm 3.0000 sec 3.0000 sec $0.00 $0.035

3.0000 sec 3.0000 sec $0.00 $0.035

1.0000 sec 1.0000 sec $0.00 $0.011

3.0000 sec 3.0000 sec $0.00 $0.031

3.0000 sec 3.0000 sec $0.00 $0.031

3.0000 sec 3.0000 sec $0.00 $0.031

H Coil, Magnetic, Brake Actuator 7.0000 sec 7.0000 sec $0.00 $0.071

H Piston, Actuator, Brake 12.0000 sec 12.0000 sec- $0.122

0.0000 sec 0.0000 sec $0.00 $0.002

H Piston, Actuator, Washed 3.0000 sec 3.0000 sec- $0.032

--

-

---

0.0000 sec 0.0000 sec $0.00 $0.002

--

-

---

--

-

---

--

-

---

H Piston, Actuator, Brake, Machined 3.0000 sec 3.0000 sec- $0.032

--

-

---

0.0000 sec 0.0000 sec $0.00 $0.002

H Piston, Actuator, Brake - Material 0.0000 sec 0.0000 sec $0.08 $0.002

--

-

---
- - - - - -

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 Wiper, 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

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- - - - - -

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- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

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 H Retainer, Plunger, Actuator, Brake 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec - $0.03 1

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 Wire, 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)

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- - - - - -

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- - - - - -

- - - - - -

- - - - - -

- - - - - -

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

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- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

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 H Pin, Brake, Pivot, Main 9.0000 sec 9.0000 sec 9.0000 sec 9.0000 sec - $0.09 1

- - - - - -

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

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- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

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, Weldment, 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, Weldment, Washed 7.0000 sec 7.0000 sec - $0.11 1

0.0000 sec 0.0000 sec $0.00 $0.00 1

- - - - - -

H Brake Pedal Arm, Weldment, 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 Weldment, 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 Weldment 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 Weldment (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 - Washed 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 - Washed 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 Assembly

Level Symbol 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 - 

2 H Bracket, Brake to Mounting Bracket - Material H Bracket, Brake to Mounting Bracket - 

1 H Weld Nut, Bracket, Brake H Weld Nut, Bracket, Brake

1 H Weld Nut, Bracket, Brake H Weld Nut, Bracket, Brake

0 H Bolt, Brake Mounting Bracket H Bolt, Brake Mounting Bracket

0 H Brake Mounting Bracket Asm. H Brake Mounting Bracket Asm.

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 Asm H Brake Position Sensor & Brkt Asm

2 H Brake Position Sensor Asm H Brake Position Sensor Asm

2 H Brake Position Sensor Bracket Asm H Brake Position Sensor Bracket As

3 H Brake Position Sensor Bracket - Molded H Brake Position Sensor Bracket 

4 H Brake Position Sensor Bracket - Material H Brake Position Sensor Bracket 

3 H Brake Position Sensor Brkt Insert H Brake Position Sensor Brkt Inse

1 H Brake Pedal Actuator Asm H Brake Pedal Actuator Asm

2 H Housing, Actuator, Brake H Housing, Actuator, Brake

3 H Housing, Actuator, Brake - Machined H Housing, Actuator, Brake - Mac

4 H Housing, Actuator, Brake - Cut Block H Housing, Actuator, Brake - C

5 H Housing, Actuator, Brake - Extrusion H Housing, Actuator, Brake - E

2 H Ball, Plug, Stainless Steel, 3.4 mm H Ball, Stainless Steel, 3.4 mm

2 H Coil, Magnetic, Brake Actuator H Coil, Magnetic, Brake Actuator

2 H Piston, Actuator, Brake H Piston, Actuator, Brake

3 H Piston, Actuator, Washed H Piston, Actuator, Washed

4 H Piston, Actuator, Brake, Machined H Piston, Actuator, Brake, Mac

5 H Piston, Actuator, Brake - Material H Piston, Actuator, Brake - Ma

3 H O-Ring, Piston, Actuator H O-Ring, Piston, Actuator

2 H Spring, Coil, Piston, Actuator, Brake H Spring, Coil, Piston, Actuator, Br

2 H Cap, Piston Spring Asm H Cap, Piston Spring Asm

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 Asm, Brake, Actuator H Plunger Asm, Brake, Actuator

3 H Shaft, Actuator, Brake H Shaft, Actuator, Brake

4 H Shaft, Actuator, Brake - Machined H Shaft, Actuator, Brake - Mach

5 H Shaft, Actuator, Brake - Material H Shaft, Actuator, Brake - Ma

3 H Bell Housing, Actuator, Brake H Bell Housing, Actuator, Brake

4 H Bell Housing, Actuator, Brake - Machined H Bell Housing, Actuator, Brak

5 H Bell Housing, Actuator, Brake - Material H Bell Housing, Actuator, Brak

3 H Foam Wiper, Actuator, Brake H Foam Wiper, Actuator, Brake

3 H Cap, Plunger, Actuator H Cap, Plunger, Actuator

4 H Cap, Plunger, Actuator - Material H Cap, Plunger, Actuator - Mater

3 H Stud and O-Ring Asm, Actuator H Stud and O-Ring Asm, Actuator
4 H Stud, Threaded, Actuator, Brake H Stud, Threaded, Actuator, Br

5 H Stud, Threaded, Actuator, Brake - Machined H Stud, Threaded, Actuator, 

6 H Stud, Threaded, Actuator, Brake - Material H Stud, Threaded, Actuato

4 H O-Ring, Stud, Actuator, Brake H O-Ring, Stud, Actuator, Brake

4 H Retainer, Plunger, Actuator, Brake H Retainer, Plunger, Actuator, 

5 H Retainer, Plunger, Actuator, Brake - Machined H Retainer, Plunger, Actuato

6 H Retainer, Plunger, Actuator, Brake - Material H Retainer, Plunger, Actua

2 H Wire, Retaining, Plunger, Brake, Actuator H Wire, Retaining, Plunger, Brake, Act

2 H Spring, Coil, Actuator, Brake H Spring, Coil, Actuator, 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, Actuator, Brake H Clevis, Actuator, Brake

3 H Clevis, Actuator, Brake, Machined H Clevis, Actuator, Brake, Machin

4 H Clevis, Actuator, Brake - Turned H Clevis, Actuator, Brake - Tur

5 H Clevis, Actuator, Brake, Material H Clevis, Actuator, Brake, Ma

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 - M

2 H Pivot, Brake Pedal Return Spring - Material H Pivot, Brake Pedal Return Spring - M

1 H Latch, Brake Pedal Return Spring - Molded H Latch, Brake Pedal Return Spring - M

2 H Latch, Brake Pedal Return Spring - Material H Latch, Brake Pedal Return Spring - M

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 - 

4 H Bracket, Brake Pedal Casting H Bracket, Brake Pedal Casting

5 H Bracket, Brake Pedal Casting - Material H Bracket, Brake Pedal Castin

1 H Pushnut, Fastener - Brake Pedal Pivot H Pushnut, Fastener

1 H Screw - Brake Pedal, Stoplight Switch Brkt H Screw - Brake Pedal, Stoplight Switch B

1 H Bracket, Brake Pedal Brakelight Switch H Bracket, Brake Pedal Brakelight Swit

2 H Bracket, Brake Pedal Brakelight Switch Material H Bracket, Brake Pedal Brakelight Swit

1 H Brake Pedal and Simulator Asm H Brake Pedal and Simulator Asm

2 H Brake Pedal Arm Subassembly H Brake Pedal Arm Subassembly

3 H Brake Pedal Arm, Weldment, Painted H Brake Pedal Arm, Weldment, Pa

4 H Brake Pedal Arm, Weldment, Washed H Brake Pedal Arm, Weldment, 

5 H Brake Pedal Arm, Weldment, Machined H Brake Pedal Arm, Weldme

6 H Brake Pedal, Partial Weldment, Machined H Brake Pedal, Partial We

7 H Brake Pedal Arm Partial Weldment H Brake Pedal Arm Pa

8 H Brake Pedal Arm, Swaged H Brake Pedal Arm, 

9 H Brake Pedal Arm Partial Weldment (stage 1) H Brake Pedal Ar

# H Brake Pedal Arm Stamping

11 H Brake Pedal Arm Material

9 H Pin, Brake Pedal Spring Pivot H Pin, Brake Ped

# H Pin, Brake Pedal Spring Pivot - Machined

11 H Pin, Brake Pedal Spring Pivot - Material

9 H Tube, Pivot, Brake Pedal Arm H Tube, Pivot, Br

8 H Bar, Brake Pedal Spring H Bar, Brake Pedal 

9 H Bar, Brake Pedal Spring - machined H Bar, Brake Ped

# H Bar, Brake Pedal Spring - cut

11 H Bar, Brake Pedal Spring - bar stock

6 H Bracket, Brake Pedal Stop H Bracket, Brake Pedal S
7 H Bracket, Brake Pedal Stop - Material H Bracket, Brake Pedal 

6 H Pedal Contact, Brake Pedal H Pedal Contact, Brake P

7 H Pedal Contact, Brake Pedal, Raw Material H Pedal Contact, Brake 

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, R

2 H Simulator, Brake Pedal Asm H Simulator, Brake Pedal Asm

3 H Housing, Simlator, Brake Pedal H Housing, Simlator, Brake Pedal

4 H Housing Asm, Brake, Simulator H Housing Asm, Brake, Simula

5 H Housing, Simulator, Brake - Machined H Housing, Simulator, Brake 

6 H Housing, Simulator, Brake - Casting H Housing, Simulator, Br

7 H Pin, Simulator - Actuator H Pin, Simulator - Actu

8 H Pin, Simulator - Actuator - Washed H Pin, Simulator - A

9 H Pin, Simulator - Actuator - Machined H Pin, Simulator 

# H PIn, Simulator - Actuator - Material

7 H Housing, Simulator, Brake - Material H Housing, Simulator, B

4 H Pin, Dowel, Split, Simulator Housing H Pin, Dowel, Split, Simulator Ho

4 H Bushing, Brake Simulator Housing H Bushing, Brake Simulator Ho

3 H Bumper, Leaf Spring, Simulator H Bumper, Leaf Spring, Simulator

4 H Bumper, Leaf Spring, Simulator - Material H Bumper, Leaf Spring, Simulato

3 H Spring, Leaf, Simulator Asm H Spring, Leaf, Simulator Asm

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 - Mater

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 Asm H Spring, Rubber Bumper, Brake 

4 H Spring, Rubber Bumper, Brake Pedal - Molded H Spring, Rubber Bumper, Bra

5 H Spring, Rubber Bumper, Brake Pedal - Material H Spring, Rubber Bumper, Bra

4 H Plate, Spring, Rubber Bumper H Plate, Spring, Rubber Bumpe

5 H Plate, Spring, Rubber Bumper, Material H Plate, Spring, Rubber Bump

3 H Cover, Simulator, Brake Pedal H Cover, Simulator, Brake Pedal

4 H Cover, Simulator, Brake Pedal - Washed H Cover, Simulator, Brake Ped

5 H Cover, Simulator, Brake Pedal - Deburred H Cover, Simulator, Brake P

6 H Cover, Simulator, Brake Pedal - Stamped H Cover, Simulator, Brak

7 H Cover, Simulator, Brake Pedal - Material H Cover, Simulator, Bra

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 P

0 H Screw, Brake Pedal Sensor H Screw, Brake Pedal Sensor

Assembly Totals

Analyzed Subs: 78

Unanalyzed Subs: 17

Parts: 65

Fasteners: 19

Parts+Unanalyzed: 82
Design Profit®

Copyright 2005© Munro & Associates, Inc.
Qty Material

rake to Mounting Bracket

1

t, Brake to Mounting Bracket - Stamped1 Steel - 1018

ket, Brake to Mounting Bracket - Material

1 Steel - 1018

ut, Bracket, Brake1 Commodity Pricing

ut, Bracket, Brake1 Commodity Pricing

 Mounting Bracket2 Commodity Pricing

unting Bracket Asm.1

 Mounting Bracket

2 Commodity Pricing

al Subassembly1

Position Sensor & Brkt Asm1

e Position Sensor Asm1 Commodity Pricing

e Position Sensor Bracket Asm1

rake Position Sensor Bracket - Molded1 PA66 GF30

 Brake Position Sensor Bracket - Material

1 PA66 GF30

rake Position Sensor Brkt Insert2 Commodity Pricing

Pedal Actuator Asm1 Commodity Pricing

sing, Actuator, Brake1

ousing, Actuator, Brake - Machined1

 Housing, Actuator, Brake - Cut Block1

H Housing, Actuator, Brake - Extrusion

1 Aluminum - 7075-T6

Stainless Steel, 3.4 mm5 Stainless Steel - Austenitic

 Magnetic, Brake Actuator1 Commodity Pricing

on, Actuator, Brake2

ston, Actuator, Washed1

 Piston, Actuator, Brake, Machined1

H Piston, Actuator, Brake - Material

1 Aluminum - 6061-T6

-Ring, Piston, Actuator1 Commodity Pricing

ng, Coil, Piston, Actuator, Br1 Commodity Pricing

 Piston Spring Asm1

ap, Rim, Stamped1

 Cap, Rim - Material

1 Stainless Steel - 304

ap, Button, Molded1 Commodity Pricing

p, Brake Actuator Piston

1 Commodity Pricing

l, Brake Pedal Actuator Asm1

, Actuator, Brake1

ger Asm, Brake, Actuator1

haft, Actuator, Brake1

 Shaft, Actuator, Brake - Machined1

H Shaft, Actuator, Brake - Material

1 Stainless Steel - Austenitic

ell Housing, Actuator, Brake1

 Bell Housing, Actuator, Brake - Machined1

H Bell Housing, Actuator, Brake - Material

1 Aluminum - 6061-T6

oam Wiper, Actuator, Brake1 Commodity Pricing

ap, Plunger, Actuator1

 Cap, Plunger, Actuator - Material

1 Stainless Steel - 304

tud and O-Ring Asm, Actuator1
 Stud, Threaded, Actuator, Brake1

H Stud, Threaded, Actuator, Brake - Machined1

H Stud, Threaded, Actuator, Brake - Material

1 Stainless Steel - Austeniti

 O-Ring, Stud, Actuator, Brake1 Commodity Pricing

 Retainer, Plunger, Actuator, Brake1

H Retainer, Plunger, Actuator, Brake - Machined1

H Retainer, Plunger, Actuator, Brake - Material

1 Stainless Steel - Austeniti

 Retaining, Plunger, Brake, Actuator1 Stainless Steel - 304

ng, Coil, Actuator, Brake1 Commodity Pricing

 Ring - Actuator, Brake

1 Commodity Pricing

Lock, Actuator, Brake1 Commodity Pricing

is, Actuator, Brake1 Stainless Steel - Austenitic

evis, Actuator, Brake, Machined1

 Clevis, Actuator, Brake - Turned1

H Clevis, Actuator, Brake, Material

1 Stainless Steel - 304

sor, Pressure, Brake Pedal1 Commodity Pricing

2 Commodity Pricing

ring, Brake Pedal Simulator1 Commodity Pricing

Coil, Brake Pedal Return1 Commodity Pricing

Brake Pedal Return Spring - Molded1

, Brake Pedal Return Spring - Material

1 PA66 GF30

Brake Pedal Return Spring - Molded1

h, Brake Pedal Return Spring - Material

1 PBT GF20

ake, Pivot, Main1

Brake, Pivot, Machined1

n, Brake, Pivot, Material

1 Steel - 1018

1

ket, Brake Pedal Machined1

racket, Brake Pedal Casting - Trimmed1

 Bracket, Brake Pedal Casting1

H Bracket, Brake Pedal Casting - Material

1 Aluminum - 332

1 Commodity Pricing

 Brake Pedal, Stoplight Switch Brkt1 Commodity Pricing

t, Brake Pedal Brakelight Switch1

ket, Brake Pedal Brakelight Switch Material

1 Steel - 1018

Pedal and Simulator Asm1

e Pedal Arm Subassembly1

rake Pedal Arm, Weldment, Painted1

 Brake Pedal Arm, Weldment, Washed1

H Brake Pedal Arm, Weldment, Machined1

H Brake Pedal, Partial Weldment, Machined1

H Brake Pedal Arm Partial Weldment1

H Brake Pedal Arm, Swaged1

H Brake Pedal Arm Partial Weldment (stage 1)1

H Brake Pedal Arm Stamping1

H Brake Pedal Arm Material

H Pin, Brake Pedal Spring Pivot1

H Pin, Brake Pedal Spring Pivot - Machined1

H Pin, Brake Pedal Spring Pivot - Material

H Tube, Pivot, Brake Pedal Arm1

H Bar, Brake Pedal Spring1

H Bar, Brake Pedal Spring - machined1

H Bar, Brake Pedal Spring - cut1

H Bar, Brake Pedal Spring - bar stock

H Bracket, Brake Pedal Stop1
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

umper, Brake Pedal 1 Commodity Pricing

ushing, Brake Pedal Pivot 1 Commodity Pricing

ontact Cover, Brake Pedal 1 SBR

 Contact Cover, Brake Pedal, Raw Material 1 SBR

ulator, Brake Pedal Asm 1

ousing, Simlator, Brake Pedal 1

 Housing Asm, Brake, Simulator 1

H Housing, Simulator, Brake - Machined 1

H Housing, Simulator, Brake - Casting 1

H Pin, Simulator - Actuator 1

H Pin, Simulator - Actuator - Washed 1

H Pin, Simulator - Actuator - Machined 1

H PIn, Simulator - Actuator - Material 1

H Housing, Simulator, Brake - Material 1 Aluminum - AlSi9Cu3

 Pin, Dowel, Split, Simulator Housing 2 Commodity Pricing

 Bushing, Brake Simulator Housing 2 Commodity Pricing

umper, Leaf Spring, Simulator 1

 Bumper, Leaf Spring, Simulator - Material 1 TPE

pring, Leaf, Simulator Asm 1

 Spring, Leaf, Simulator 1 Commodity Pricing

 Pad #2, Leaf Spring 1

H Pad #2, Leaf Spring - Material 1 Nylon 6 

 Pad, Spring, Leaf 1

H Pad, Spring, Leaf - Material 1 Nylon 6/6 (GF)

pring, Rubber Bumper, Brake Pedal Asm 1

 Spring, Rubber Bumper, Brake Pedal - Molded 1

H Spring, Rubber Bumper, Brake Pedal - Material 1 EPDM

 Plate, Spring, Rubber Bumper 1

H Plate, Spring, Rubber Bumper, Material 1

over, Simulator, Brake Pedal 1

 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

-Ring, NVH, Simulator Shaft 3 Commodity Pricing

crew, Cover, Simulator, Brake Pedal 2

ke 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

mmodity 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

nless Steel - Austenitic $0.00 0.0003 lb

mmodity 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

mmodity 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

nless Steel - 304 $0.01 0.0045 lb

mmodity Pricing $0.95 0.0345 lb

$0.00 0.0021 lb

$0.00 0.0105 lb

nless Steel - Austenitic $0.40 0.0749 lb

$0.40 0.0000 lb

$0.40

Stainless Steel - 304 $0.40

mmodity 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 - Austenitic $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)
e Brake Pedal Subassembly tab)

rake Peadl Arm, Weldment tab)
0

060600 Brake Activation Subsystem

1 00

A Assembly of Brake Activation Subsystem Components

2 01

A H Master Cylinder

3 02

A H Brake Pedal Assembly 06 06 02 - N0502 - 01

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)

Subassembly

Component

Name/Description Part Number

Item

Subsystem

Sub-Subsystem

Assembly

Assembly of Brake Activation Subsystem

Master 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=Ve

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

B Wire Harness - Pressure Sensor, Brake Pedal Cutt-off Valve (XX Pins)

C

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

Brake Fluid

Brake Lines and Hoses

Brake Control Valve

TBD

Wire Harness Connections

Wire 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, Assembly or Component row indicates design and/or manufacturing diffe

the competing technology
Material Labor Burden

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

#REF! #REF! #REF!

#REF! #REF! #REF!

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Q

T

Y/ Subsyste

m

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Notes

Manufacturing 

6 Passengers

logy Package, 02=Vehicle Class

#REF! #REF! #REF!

$ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

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$ - $ - $ -

#REF! #REF! #REF!

/or manufacturing differentials are accounted for in the quote sheet of 
End Item 

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

$ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ -

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

NEW TECHNOLOGY PACKAGE COST INFORMATION

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly

Cost Impact to 

OEM

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

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

$ - $ - $ -

$ - $ - $ -

Investment

(X1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

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