Page:1 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

0 0206 Oil Pump and Filter Subsystem

1 00 Assembly of Oil Pump and Filter Subsystem $ 0.32 $ 3.07 $ 0.47 $ 3.87 $ - $ - $ - $ - $ - $ - $ 3.87 $ - $ - $ - $ - $ - $ - $ -

2 01 Oil Pump Assembly $ 14.29 $ 7.26 $ 8.75 $ 30.30 $ 0.15 $ 1.97 $ 1.82 $ 0.76 $ 4.70 $ 0.03 $ 35.03 $ - $ - $ - $ - $ - $ - $ -

3 02 Covers $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 03 Filters $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 04 Oil Cooler $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

BASE TECHNOLOG

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description Investment

(X1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: 0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

6 05 Oil Squirter $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 70 Pipes, Hoses, Ducting $ 1.41 $ 4.06 $ 3.96 $ 9.43 $ 0.05 $ 0.61 $ 0.57 $ 0.24 $ 1.46 $ 0.04 $ 10.92 $ - $ - $ - $ - $ - $ - $ -

9 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 99 Miscellaneous $ 0.62 $ 0.65 $ 2.77 $ 4.04 $ - $ - $ - $ - $ - $ - $ 4.04 $ - $ - $ - $ - $ - $ - $ -

0 0 0

0 0 0

0 0 0

0 0 0

0 0 0

0 0 0

0 0 0

09000064810e7549.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: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

BASE TECHNOLOG

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description Investment

(X1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: 0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

SUBSYSTEM ROLL-UP $ 16.64 $ 15.04 $ 15.95 $ 47.63 $ 0.20 $ 2.58 $ 2.38 $ 0.99 $ 6.16 $ 0.07 $ 53.86 $ - $ - $ - $ - $ - $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

0 0206 Oil Pump and Filter Subsystem

1 00

2 01

3 02

4 03

5 04

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.32 $ 3.07 $ 0.47 $ 3.87 $ - $ - $ - $ - $ - $ - $ 3.87 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 14.29 $ 7.26 $ 8.75 $ 30.30 $ 0.15 $ 1.97 $ 1.82 $ 0.76 $ 4.70 $ 0.03 $ 35.03 $ - $ -

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

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

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb 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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

6 05

7 10

8 70

9 75

10 80

11 85

12 90

13 99

0 0

0 0

0 0

0 0

0 0

0 0

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 1.41 $ 4.06 $ 3.96 $ 9.43 $ 0.05 $ 0.61 $ 0.57 $ 0.24 $ 1.46 $ 0.04 $ 10.92 $ - $ -

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

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.62 $ 0.65 $ 2.77 $ 4.04 $ - $ - $ - $ - $ - $ - $ 4.04 $ - $ -

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

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

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

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

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

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

0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb 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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 16.64 $ 15.04 $ 15.95 $ 47.63 $ 0.20 $ 2.58 $ 2.38 $ 0.99 $ 6.16 $ 0.07 $ 53.86 $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

0 0206 Oil Pump and Filter Subsystem

1 00

2 01

3 02

4 03

5 04

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 05

7 10

8 70

9 75

10 80

11 85

12 90

13 99

0 0

0 0

0 0

0 0

0 0

0 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

0 0 $ -

09000064810e7549.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: 8/21/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Investment(X1

000)

$ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

0206 Oil Pump and Filter Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

1 00 Assembly of Oil Pump and Filter Subsystem $ 0.32 $ 3.07 $ 0.47 $ 3.87 $ - $ - $ - $ - $ - $ - $ 3.87 $ -

A Assembly of Auxillary Pump and Lines to Transmission 02 06 00 - N0402- 01 1 Full 1 $ 0.32 $ 3.07 $ 0.47 $ 3.87 $ - $ - $ - $ - $ - $ - $ 3.87 $ -

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

2 01 Oil Pump Assembly $ 14.29 $ 7.26 $ 8.75 $ 30.30 $ 0.15 $ 1.97 $ 1.82 $ 0.76 $ 4.70 $ 0.03 $ 35.03 $ -

A V Pump Assembly, Transmission ( sum of A1-A6) 02 06 01 - N0402- 01 1 Full 1 $ 14.29 $ 7.26 $ 8.75 $ 30.30 $ 0.15 $ 1.97 $ 1.82 $ 0.76 $ 4.70 $ 0.03 $ 35.03 $ -

A1 V Pump Asm, Transmission # 01 - N0402- 02 1 $ 0.85 $ 2.31 $ 1.07 $ 4.24 $ 0.02 $ 0.28 $ 0.25 $ 0.11 $ 0.66 $ 0.03 $ 4.93 $ -

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

A1 V Pump Asm, Transmission # 01 - N0402- 02 1 $ 0.85 $ 2.31 $ 1.07 $ 4.24 $ 0.02 $ 0.28 $ 0.25 $ 0.11 $ 0.66 $ 0.03 $ 4.93 $ -

A2 V Trans Pump, Body/Cover # 01 - N0402- 16 1 $ 1.58 $ 1.83 $ 2.50 $ 5.92 $ 0.03 $ 0.38 $ 0.35 $ 0.15 $ 0.92 $ - $ 6.83 $ -

A3 V Trans Pump Motor # 01 - N0402- 18 1 $ 1.96 $ 1.53 $ 3.22 $ 6.71 $ 0.03 $ 0.44 $ 0.40 $ 0.17 $ 1.04 $ - $ 7.76 $ -

A4 V Housing Asm., Pump Motor # 01 - N0402- 31 1 $ 8.00 $ 0.29 $ 0.44 $ 8.73 $ 0.04 $ 0.57 $ 0.52 $ 0.22 $ 1.35 $ - $ 10.08 $ -

A5 V Base Motor Asm. # 01 - N0402- 38 1 $ 0.63 $ 1.16 $ 1.33 $ 3.12 $ 0.02 $ 0.20 $ 0.19 $ 0.08 $ 0.48 $ - $ 3.60 $ -

A6 V Harness, Trans. Pump # 01 - N0402- 48 1 $ 1.05 $ 0.09 $ 0.13 $ 1.27 $ 0.01 $ 0.08 $ 0.08 $ 0.03 $ 0.20 $ - $ 1.46 $ -

A6 V Trans Pump Hyd Fitting # 01 - N0402- 55 1 $ 0.22 $ 0.04 $ 0.06 $ 0.32 $ 0.00 $ 0.02 $ 0.02 $ 0.01 $ 0.05 $ - $ 0.37 $ -

3 02 Covers $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

4 03 Filters $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 04 Oil Cooler $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 05 Oil Squirter $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

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

8 70 Pipes, Hoses, Ducting $ 1.41 $ 4.06 $ 3.96 $ 9.43 $ 0.05 $ 0.61 $ 0.57 $ 0.24 $ 1.46 $ 0.04 $ 10.92 $ -

A V Trans Pump Line Asm, Long 02 06 70 - N0402- 01 1 Full 1 $ 1.41 $ 4.06 $ 3.96 $ 9.43 $ 0.05 $ 0.61 $ 0.57 $ 0.24 $ 1.46 $ 0.04 $ 10.92 $ -

B V Trans Pump Line Asm, Short 02 06 70 - N0402- 02 1 Full 1

Pricing grouped together with Long 

Tube. $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

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

10 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A V Bolt, Transmission Pump, Long 02 06 80 - N0402- 01 4 Full 1

PIA to Assembly of Aux. Pump and 

Lines $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B V Bolt, Transmission Pump, Short 02 06 80 - N0402- 02 1 Full 1

PIA to Assembly of Aux. Pump and 

Lines $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C V Bolt, Trans. Pump Lines 02 06 80 - N0402- 03 2 Full 1

PIA to Assembly of Aux. Pump and 

Lines $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

12 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

13 99 Miscellaneous $ 0.62 $ 0.65 $ 2.77 $ 4.04 $ - $ - $ - $ - $ - $ - $ 4.04 $ -

Trans. Case and Cover Mods for Aux. Pump & Lines 02 06 99 - N0402- 01 1 Mod 1 $ 0.62 $ 0.65 $ 2.77 $ 4.04 $ - $ - $ - $ - $ - $ - $ 4.04 $ -

$ 16.64 $ 15.04 $ 15.95 $ 47.63 $ 0.20 $ 2.58 $ 2.38 $ 0.99 $ 6.16 $ 0.07 $ 53.86 $ -

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = 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

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

0

0206 Oil Pump and Filter Subsystem

1 00 Assembly of Oil Pump and Filter Subsystem

A Assembly of Auxillary Pump and Lines to Transmission 02 06 00 - N0402- 01 1 Full 1

2 01 Oil Pump Assembly

A V Pump Assembly, Transmission ( sum of A1-A6) 02 06 01 - N0402- 01 1 Full 1

A1 V Pump Asm, Transmission # 01 - N0402- 02 1

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

A1 V Pump Asm, Transmission # 01 - N0402- 02 1

A2 V Trans Pump, Body/Cover # 01 - N0402- 16 1

A3 V Trans Pump Motor # 01 - N0402- 18 1

A4 V Housing Asm., Pump Motor # 01 - N0402- 31 1

A5 V Base Motor Asm. # 01 - N0402- 38 1

A6 V Harness, Trans. Pump # 01 - N0402- 48 1

A6 V Trans Pump Hyd Fitting # 01 - N0402- 55 1

3 02 Covers

4 03 Filters

5 04 Oil Cooler

6 05 Oil Squirter

7 10 Plugs

8 70 Pipes, Hoses, Ducting

A V Trans Pump Line Asm, Long 02 06 70 - N0402- 01 1 Full 1

B V Trans Pump Line Asm, Short 02 06 70 - N0402- 02 1 Full 1

Pricing grouped together with Long 

Tube.

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

9 75 Brackets $ - $ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

10 80 Boltings

A V Bolt, Transmission Pump, Long 02 06 80 - N0402- 01 4 Full 1

PIA to Assembly of Aux. Pump and 

Lines

B V Bolt, Transmission Pump, Short 02 06 80 - N0402- 02 1 Full 1

PIA to Assembly of Aux. Pump and 

Lines

C V Bolt, Trans. Pump Lines 02 06 80 - N0402- 03 2 Full 1

PIA to Assembly of Aux. Pump and 

Lines

11 85 Sealing Elements

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

12 90 Bearings Elements Misc

13 99 Miscellaneous

Trans. Case and Cover Mods for Aux. Pump & Lines 02 06 99 - N0402- 01 1 Mod 1

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = 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

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

0206 Oil Pump and Filter Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

1 00 Assembly of Oil Pump and Filter Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 01 Oil Pump Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 02 Covers $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

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

4 03 Filters $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 04 Oil Cooler $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 05 Oil Squirter $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

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

8 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

9 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

10 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

11 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

12 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

13 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

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

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

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

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

0

0206 Oil Pump and Filter Subsystem

1 00 Assembly of Oil Pump and Filter Subsystem

2 01 Oil Pump Assembly

3 02 Covers

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

4 03 Filters

5 04 Oil Cooler

6 05 Oil Squirter

7 10 Plugs

8 70 Pipes, Hoses, Ducting

9 75 Brackets

10 80 Boltings

11 85 Sealing Elements

12 90 Bearings Elements Misc

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

13 99 Miscellaneous $ - $ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

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)

$ - $ -

$ - $ -

09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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 1A V Pump Asm, Transmission 020601-N0402-01 1

Assembly Aux. Trans. Pump to 

Engine

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM Transmission Assembly, OEM, LC 114 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.85 $0.13 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.98 $0.00

2 2A V Trans Pump Line Asm, Long 020670-N0402-01 1

Assembly Connection LineLong from Pump to 

Transmission Housing

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM Transmission Assembly, OEM, LC 138 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.70 $0.11 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 $0.81 $0.00

3 3A V Trans Pump Line Asm, Short 020670-N0402-02 1

Assembly Connection LineShort from Pump to 

Transmission Housing

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM Transmission Assembly, OEM, LC 138 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.70 $0.11 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 $0.81 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop 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)

Transmission Housing Covered by ICM LC

4 4A Wire Harness Connection to Aux. Pump, SGCM, 

Fuse Block Aux. 020699-N0402-01A 1

Assemble Trans. Aux. Pump 

Connector

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM Transmission Assembly, OEM, LC 120 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.81 $0.13 $0.94 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.94 $0.94 $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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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

Mild Hybrid - Start-Stop 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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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

Mild Hybrid - Start-Stop 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)

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 1A V Bolt, Transmission Pump, Long 020680-N0402-01 4 S $0.00 $0.05 $0.00 $0.20 $0.20

2 2A V Bolt, Transmission Pump, Short (Tube) 020680-N0402-02 1 S $0.00 $0.02 $0.00 $0.02 $0.02

3 3A V Bolt, Trans. Pump Lines 020680-N0402-03 2 S $0.00 $0.05 $0.00 $0.10 $0.10

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

"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 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.32

Material Labor Burden TMC Scrap SG&A Profit ED&T Total $3.87

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.

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

Mark-up $3.87

T1 or OEM Total Manufacturing Cost: $0.32 $3.07 $0.47 $3.87 $0.00 $0.00 $0.00 $0.00 $0.00 $3.87

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: $0.32 $3.07 $0.47 $3.87 $0.00 $0.00 $0.00 $0.00 $0.00 $3.87 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $3.87

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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

Mild Hybrid - Start-Stop 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

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:09000064810e7549.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:8/21/2012

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 V Pump Asm, Transmission 020601-N0402-01

2A V Trans Pump Line Asm, Long 020670-N0402-01

3A V Trans Pump Line Asm, Short 020670-N0402-02

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

$0.85 $0.13 $0.98 $0.00 $0.00 $0.00 $0.00 $0.00 Manual load pump to trans housing, hand start fasteners x4, manual rundown x4 (Completed over two 

Stations) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 48 1 1 31.5 1.0 1.0

$0.70 $0.11 $0.81 $0.00 $0.00 $0.00 $0.00 $0.00 Manual position hydraulic tube to pump and trans case, had start two fasteners, manual rundown x2 5 2 10 100 47 4700 96 37.60 85% 113 31.96 35 1 1 26 1.0 1.0

$0.70 $0.11 $0.81 $0.00 $0.00 $0.00 $0.00 $0.00 Manual position hydraulic tube (short) to pump and trans case, had start two fasteners, manual rundown 

x2. (Note long tube and short tube assembly operations likely combined over two stations) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 38 1 1 26 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

4A Wire Harness Connection to Aux. Pump, SGCM, 

Fuse Block Aux. 020699-N0402-01A

Purchase Part - High Impact Item (Full Cost Mapping)

x2. (Note long tube and short tube assembly operations likely combined over two stations)

$0.81 $0.13 $0.94 $0.00 $0.00 $0.00 $0.00 $0.00 3 Conection Points , Hybrid Pump Driver, Aux. Pump, and Starter Generator Control Module (SGCM) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 30 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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 - High Impact Item (Full Cost Mapping)

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

1A V Bolt, Transmission Pump, Long 020680-N0402-01

2A V Bolt, Transmission Pump, Short (Tube) 020680-N0402-02

3A V Bolt, Trans. Pump Lines 020680-N0402-03

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

$0.02

$0.10

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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

$3.07 $0.47 $3.87 $0.00 $0.00 $0.00 $0.00 $0.00

$3.87

2

Notes: 

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

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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 V Pump Asm, Transmission 020601-N0402-01

2A V Trans Pump Line Asm, Long 020670-N0402-01

3A V Trans Pump Line Asm, Short 020670-N0402-02

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

114 31.50 1.00

138 26.00 1.00

138 26.00 1.00

4A Wire Harness Connection to Aux. Pump, SGCM, 

Fuse Block Aux. 020699-N0402-01A

Purchase Part - High Impact Item (Full Cost Mapping)

120 30.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

1A V Bolt, Transmission Pump, Long 020680-N0402-01

2A V Bolt, Transmission Pump, Short (Tube) 020680-N0402-02

3A V Bolt, Trans. Pump Lines 020680-N0402-03

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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 1A Trans. Case and Cover Mods for Aux. Pump & 

Lines 020699-N0402-02 1

Additional Machining of Case 

and Cover

OEM Assembly, Mark-up 

Covered by ICM Aluminum-A380, Cast CNC Operator-OEM Transfer machining line, Transmission cases, OEM 117 1 4 1 0.563 $1.10 $75.92 $81.00 $324.00 $0.62 $0.65 $2.77 $4.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.04 $4.04 $0.62

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

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

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

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

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

Costs Broken Out In

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

Mild Hybrid - Start-Stop 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.

Accounted for extra material to mount pump 

and lines. With minor material add 

estimated cast fab times and rates would 

stay the same.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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

Mild Hybrid - Start-Stop 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

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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

Mild Hybrid - Start-Stop 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)

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly. 9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.62

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

Mark-up $4.04

T1 or OEM Total Manufacturing Cost: $0.62 $0.65 $2.77 $4.04 $0.00 $0.00 $0.00 $0.00 $0.00 $4.04

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

Supplier for Subassembly.

3

1

Notes: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- 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: $0.62 $0.65 $2.77 $4.04 $0.00 $0.00 $0.00 $0.00 $0.00 $4.04 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $4.04

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Transmission Assembly

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Auxillary Pump and Lines to Transmission Part Number: 020601-N0402-01 Weekly Component Volume: Packaging Specification: NA

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

Mild Hybrid - Start-Stop 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:09000064810e7549.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:8/21/2012

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 Trans. Case and Cover Mods for Aux. Pump & 

Lines 020699-N0402-02

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

$0.65 $2.77 $4.04 $0.00 $0.00 $0.00 $0.00 $0.00 Addition machining into case and cover would be incorporated into existing machining lines. Only 

account for additional machining time. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 123 1 1 123.0 1.0 4.0

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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

$0.65 $2.77 $4.04 $0.00 $0.00 $0.00 $0.00 $0.00

$4.04

2

Notes: 

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

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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 Trans. Case and Cover Mods for Aux. Pump & 

Lines 020699-N0402-02

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

117 30.75 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Line Asm, Long (short included as well) Part Number: 020670-N0402-01/02 Weekly Component Volume: Packaging Specification:

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

V Tube End

7001-N0402-76 1

Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 360 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.11 $0.03 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.00

3 7001-N0402-76-01 1 Bar Feed T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-6062, Bar CNC Operator

CNC Turning, SS, BF, DA 88 1 1 1 0.106 $1.45 $36.98 $20.48 $20.48 $0.15 $0.42 $0.23 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 $0.81 $0.15

4

V Protective Cover, Tube Asm.

7001-N0402-67 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals

6000 0.5 1 1 0.125 $0.84 $42.73 $15.50 $15.50 $0.11 $0.00 $0.00 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.11

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

Mild Hybrid - Start-Stop 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)

4 7001-N0402-67 1 Stamp @ Bottom. 6000 0.5 1 1 0.125 $0.84 $42.73 $15.50 $15.50 $0.11 $0.00 $0.00 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.11

5 V Guide, Trans. Line, Long 7001-N0402-68 2

Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly

Washing Equipment, LC

450 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.09 $0.02 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.22 $0.00

6 7001-N0402-68-01 2 Bar Feed T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-6062, Bar CNC Operator

CNC Turning, SS, BF, DA 88 1 1 1 0.090 $1.45 $36.98 $20.48 $20.48 $0.13 $0.42 $0.23 $0.78 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.78 $1.57 $0.26

7 V Support Bar, Tube, Short, 7001-N0402-73 1

Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly

Washing Equipment, LC

450 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.09 $0.02 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

8 7001-N0402-73-01 1 Bar Feed T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-6062, Bar CNC Operator

CNC Turning, SS, BF, DA 124 1 1 1 0.079 $1.45 $36.98 $20.48 $20.48 $0.12 $0.30 $0.16 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.58 $0.58 $0.12

9

V Tube, Trans Line, Short

7001-N0402-72 1 Bend/Flare end T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-3000S, Coil Cut/Punch/Forming Operator

Hydro/CNC Form, SMS, LMC 92 0.5 1 1 0.022 $0.84 $42.73 $50.00 $50.00 $0.02 $0.23 $0.54 $0.79 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.79 $0.79 $0.02

10

V Tube, Trans Line, Long

7001-N0402-66 1 Bend/Flare ends T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-3000S, Coil Cut/Punch/Forming Operator

Hydro/CNC Form, SMS, LMC 46 0.5 1 1 0.184 $0.84 $42.73 $50.00 $50.00 $0.15 $0.47 $1.10 $1.72 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.72 $1.72 $0.15

11

V Base, External Filter

7001-N0402-60 1 Plate T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

Plating/Coating Operator Plate/Finish, SMS, MHC

720 2 1 1 0.000 $0.00 $40.84 $125.00 $125.00 $0.00 $0.11 $0.17 $0.29 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.29 $0.29 $0.00

12 7001-N0402-60-01 1

Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

CNC Operator Washing Equipment, LC

360 0.5 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.05 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

13 7001-N0402-60-02 1

V Base, External Filter, MachineT1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1040S, Bar

CNC Operator

CNC Turning, SS, BF, DA 88 1 1 1 0.186 $0.80 $36.98 $20.48 $20.48 $0.15 $0.42 $0.23 $0.80 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.80 $0.80 $0.15

14 V Trans Pump Line Asm, Short 7001-N0402-70 1 Solder T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

Welding/Soldering Operator

Mech Assembly, MC, Base 514 0.25 1 1 0.000 $0.00 $41.55 $30.00 $30.00 $0.00 $0.02 $0.06 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

15 7001-N0402-70-01 1 Manual Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

360 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

16 V Trans Pump, External Filter 7001-N0402-59 1 Manual Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

360 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

17 V Trans Pump Line Asm, Long 7001-N0402-64 1 Manual Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

360 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

18

V Tube & Cover Asm.

7001-N0402-65 1 Project Weld T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

Welding/Soldering Operator

Mech Assembly, MC, Base 141 0.25 1 1 0.000 $0.00 $41.55 $30.00 $30.00 $0.00 $0.07 $0.21 $0.29 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.29 $0.29 $0.00

T1 Assembly, Mark-up Applied General Assembly Mech Assembly, LC, Base

19 V Transmission 7001-N0402-01 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

58 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.67 $0.52 $1.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.19 $1.19 $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

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

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

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

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Line Asm, Long (short included as well) Part Number: 020670-N0402-01/02 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

27 V Filter, Pump Asm. 7001-N0402-62 1 S $0.00 $0.15 $0.00 $0.15 $0.15

28 V O-Ring, External Filter 7001-N0402-63 1 S $0.00 $0.07 $0.00 $0.07 $0.07

28 V O-ring, Long Tube Asm. 7001-N0402-69 1 S $0.00 $0.08 $0.00 $0.08 $0.08

29 V Collar, Tube Asm., Short 7001-N0402-74 1 S $0.00 $0.02 $0.00 $0.02 $0.02

29 V Metal Seal, Tube, Short 7001-N0402-75 1 S $0.00 $0.01 $0.00 $0.01 $0.01

"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 29 V Metal Seal, Tube, Short 7001-N0402-75 1 S $0.00 $0.01 $0.00 $0.01 $0.01

29 V Foam Seal, Trans Pump Line 7001-N0402-77 1 S $0.00 $0.01 $0.00 $0.01 $0.01

29 V O-ring, Trans Pump Line 7001-N0402-78 2 S $0.00 $0.06 $0.00 $0.11 $0.11

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$1.41

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

Mark-up $9.43

T1 or OEM Total Manufacturing Cost: $1.41 $4.06 $3.96 $9.43 $0.00 $0.00 $0.00 $0.00 $0.00 $9.43

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 ----- ----- ----- $0.05 $0.61 $0.57 $0.24 $1.46

Base Cost Impact to Vehicle: $1.41 $4.06 $3.96 $9.43 $0.05 $0.61 $0.57 $0.24 $1.46 $10.89 $0 $0

Packaging Cost: $0.04

Net Cost Impact to Vehicle: $10.92

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 Other #1 Other #1 Other #2 Other #2 Other #3 Other #3 

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

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 

3

1

Notes: 

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

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, 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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Line Asm, Long (short included as well) Part Number: 020670-N0402-01/02 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Tube End

7001-N0402-76

7001-N0402-76-01

V Protective Cover, Tube Asm.

7001-N0402-67

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

$0.11 $0.03 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.42 $0.23 $0.81 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 1 1 41 1.0 1.0

$0.00 $0.00 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Single part per hit 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 1 1 0.6 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

7001-N0402-67

V Guide, Trans. Line, Long 7001-N0402-68

7001-N0402-68-01

V Support Bar, Tube, Short, 7001-N0402-73

7001-N0402-73-01

V Tube, Trans Line, Short

7001-N0402-72

V Tube, Trans Line, Long

7001-N0402-66

V Base, External Filter

7001-N0402-60

7001-N0402-60-01

7001-N0402-60-02

V Trans Pump Line Asm, Short 7001-N0402-70

7001-N0402-70-01

V Trans Pump, External Filter 7001-N0402-59

V Trans Pump Line Asm, Long 7001-N0402-64

V Tube & Cover Asm.

7001-N0402-65

$0.00 $0.00 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Single part per hit 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 1 1 0.6 1.0 1.0

$0.17 $0.05 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 191 18.80 85% 225 15.98 8 1 1 8 1.0 1.0

$0.84 $0.47 $1.57 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 191 18.80 85% 225 15.98 41 1 1 41 1.0 1.0

$0.09 $0.02 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 1 8 1.0 1.0

$0.30 $0.16 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 29 1 1 29 1.0 1.0

$0.23 $0.54 $0.79 $0.00 $0.00 $0.00 $0.00 $0.00 Tube form and flare, Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 39 1 1 39 1.0 1.0

$0.47 $1.10 $1.72 $0.00 $0.00 $0.00 $0.00 $0.00 Tube form and flare, Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 79 1 1 79 1.0 1.0

$0.11 $0.17 $0.29 $0.00 $0.00 $0.00 $0.00 $0.00 Zinc plating, batch processed Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 1 5 1.0 1.0

$0.05 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.42 $0.23 $0.80 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 1 1 41 1.0 1.0

$0.02 $0.06 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Solder Tube end in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 7 2 1 7 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Low level Assembly - place metal seal, collar and support bar on tube. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 18 9 1 10 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Assembly - place O ring on filter and place in metal base 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 11 1 10 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Low level Assembly - place guides on tube - flare ends 5 2 10 100 47 4700 96 37.60 85% 113 31.96 32 14 1 10 1.0 1.0

$0.07 $0.21 $0.29 $0.00 $0.00 $0.00 $0.00 $0.00 Projection weld protective cover to tube 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25.6 9 1 25.6 1.0 1.0

V Transmission 7001-N0402-01

Purchase Part - High Impact Item (Full Cost Mapping)

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

$0.67 $0.52 $1.19 $0.00 $0.00 $0.00 $0.00 $0.00 Bolt Pump long and short pump lines to transmission pump 5 2 10 100 47 4700 96 37.60 85% 113 31.96 125 26 1 125 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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

V Filter, Pump Asm. 7001-N0402-62

V O-Ring, External Filter 7001-N0402-63

V O-ring, Long Tube Asm. 7001-N0402-69

V Collar, Tube Asm., Short 7001-N0402-74

V Metal Seal, Tube, Short 7001-N0402-75

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

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

$0.00

$0.15

$0.07

$0.08

$0.02

V Metal Seal, Tube, Short 7001-N0402-75 $0.01

V Foam Seal, Trans Pump Line 7001-N0402-77

V O-ring, Trans Pump Line 7001-N0402-78

$0.01

$0.01

$0.11

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$4.06 $3.96 $9.43 $0.00 $0.00 $0.00 $0.00 $0.00

$9.43

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Tube End

7001-N0402-76

7001-N0402-76-01

V Protective Cover, Tube Asm.

7001-N0402-67

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! -

360 10.00 1.00

88 41.00 1.00

7001-N0402-67 6000 0.60 0.50

V Guide, Trans. Line, Long 7001-N0402-68

7001-N0402-68-01

V Support Bar, Tube, Short, 7001-N0402-73

7001-N0402-73-01

V Tube, Trans Line, Short

7001-N0402-72

V Tube, Trans Line, Long

7001-N0402-66

V Base, External Filter

7001-N0402-60

7001-N0402-60-01

7001-N0402-60-02

V Trans Pump Line Asm, Short 7001-N0402-70

7001-N0402-70-01

V Trans Pump, External Filter 7001-N0402-59

V Trans Pump Line Asm, Long 7001-N0402-64

V Tube & Cover Asm.

7001-N0402-65

6000 0.60 0.50

450 8.00 1.00

88 41.00 1.00

450 8.00 1.00

124 29.00 1.00

92 39.00 0.50

46 79.00 0.50

720 5.00 2.00

360 10.00 0.50

88 41.00 1.00

514 7.00 0.25

360 10.00 0.25

360 10.00 0.25

360 10.00 0.25

141 25.60 0.25

V Transmission 7001-N0402-01

Purchase Part - High Impact Item (Full Cost Mapping)

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

58 62.50 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

V Filter, Pump Asm. 7001-N0402-62

V O-Ring, External Filter 7001-N0402-63

V O-ring, Long Tube Asm. 7001-N0402-69

V Collar, Tube Asm., Short 7001-N0402-74

V Metal Seal, Tube, Short 7001-N0402-75

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

V Metal Seal, Tube, Short 7001-N0402-75

V Foam Seal, Trans Pump Line 7001-N0402-77

V O-ring, Trans Pump Line 7001-N0402-78

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Pump Asm Transmission Part Number: 0701-N0402-02 Weekly Component Volume: Packaging Specification:

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 V Trans Pump Rotor Outer 7001-N0402-04 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly

Washing Equipment, LC

360 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.11 $0.03 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.00

3 7001-N0402-04-01 1 Bar Feed/Machine T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1040S, Bar

CNC Operator

CNC Turning, SS, BF, DA 88 1 1 1 0.156 $0.80 $36.98 $20.48 $20.48 $0.12 $0.42 $0.23 $0.78 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.78 $0.78 $0.12

4

V Trans Pump Gasket

7001-N0402-10 1 V Trans Pump Gasket,Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator

Stamp/Form, Terminals

6000 0.5 1 1 0.097 $0.45 $42.73 $42.91 $42.91 $0.04 $0.00 $0.01 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.04

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

Mild Hybrid - Start-Stop 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)

4 7001-N0402-10 1 V Trans Pump Gasket,Stamp @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator 6000 0.5 1 1 0.097 $0.45 $42.73 $42.91 $42.91 $0.04 $0.00 $0.01 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.04

5 V Pump Asm, Transmission 7001-N0402-02 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

104 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.74 $0.29 $1.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.03 $1.03 $0.00

6 V Trans Pump Rotor Inner and Shaft 7001-N0402-05 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

400 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.10 $0.04 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $0.00

7 Inner 7001-N0402-06 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly

Washing Equipment, LC

450 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.09 $0.02 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

8 7001-N0402-06-01 1 Bar Feed T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1040S, Bar

CNC Operator

CNC Turning, SS, BF, DA 88 1 1 1 0.090 $0.80 $36.98 $20.48 $20.48 $0.07 $0.42 $0.23 $0.73 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.73 $0.73 $0.07

9 Shaft 7001-N0402-07 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly

Washing Equipment, LC

450 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.09 $0.02 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

10 7001-N0402-07-01 1 Bar Feed T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1040S, Bar

CNC Operator

CNC Turning, SS, BF, DA 106 1 1 1 0.050 $0.80 $36.98 $20.48 $20.48 $0.04 $0.35 $0.19 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.58 $0.58 $0.04

0

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

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

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

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 V Trans Pump Shaft Seal 7001-N0402-02 1 S $0.00 $0.15 $0.00 $0.15 $0.15

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub2 Assembly. V Trans Pump Shaft Seal 7001-N0402-02 1 S $0.00 $0.15 $0.00 $0.15 $0.15

3 V Trans Pump Housing O-Ring 7001-N0402-08 1 S $0.00 $0.08 $0.00 $0.08 $0.08

4 V Bolt M6x25 7001-N0402-09 4 S $0.00 $0.02 $0.00 $0.06 $0.06

5 V Bolt, Transmission Pump, Long 7001-N0402-13 4 S $0.00 $0.05 $0.00 $0.21 $0.21

6 V Bolt, Transmission Pump, Short 7001-N0402-14 1 S $0.00 $0.02 $0.00 $0.02 $0.02

7 V Bolt Trans Pump Lines 7001-N0402-15 1 S $0.00 $0.05 $0.00 $0.05 $0.05

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

Assembly.

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly.

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Pump Asm Transmission Part Number: 0701-N0402-02 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.85

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

Mark-up $4.24

T1 or OEM Total Manufacturing Cost: $0.85 $2.31 $1.07 $4.24 $0.00 $0.00 $0.00 $0.00 $0.00 $4.24

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 $0.28 $0.25 $0.11 $0.66

Base Cost Impact to Vehicle: $0.85 $2.31 $1.07 $4.24 $0.02 $0.28 $0.25 $0.11 $0.66 $4.89 $0 $0

Packaging Cost: $0.03

Net Cost Impact to Vehicle: $4.93

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: $0.034 $68,400 0.00% 2,250,000 60 5.00% $400 171 336 6 57447

PACKAGING CALCULATIONS: 

Packaging Type: 200 x 160 x 100

Part Size: 200 x 160 x 100

Parts/Layer: 6 x 7

Number of Layers: 8

3

1

Notes: 

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 Rack/Pallet Investment Amortization: $0.034 $68,400 0.00% 2,250,000 60 5.00% $400 171 336 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: $0.034

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Pump Asm Transmission Part Number: 0701-N0402-02 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Trans Pump Rotor Outer 7001-N0402-04

7001-N0402-04-01

V Trans Pump Gasket

7001-N0402-10

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

$0.11 $0.03 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 #REF! #REF! 85% #REF! #REF! 10 1 1 10 1.0 1.0

$0.42 $0.23 $0.78 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 1 1 41 1.0 1.0

$0.00 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Single part per hit 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 1 1 0.6 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

7001-N0402-10

V Pump Asm, Transmission 7001-N0402-02

V Trans Pump Rotor Inner and Shaft 7001-N0402-05

Inner 7001-N0402-06

7001-N0402-06-01

Shaft 7001-N0402-07

7001-N0402-07-01

0

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Trans Pump Shaft Seal 7001-N0402-02

$0.00 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Single part per hit 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 1 1 0.6 1.0 1.0

$0.74 $0.29 $1.03 $0.00 $0.00 $0.00 $0.00 $0.00 Two station two operator to assemble trans pump seal, gasket, rotor, pump motor hyd fitting and external 

filter, cover and base 5 2 10 100 47 4700 96 37.60 85% 113 31.96 138.9 1 1 69.5 1.0 2.0

$0.10 $0.04 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 Press inner and shaft together 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 1 9 1.0 1.0

$0.09 $0.02 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 1 8 1.0 1.0

$0.42 $0.23 $0.73 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 1 1 41 1.0 1.0

$0.09 $0.02 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 #REF! #REF! 85% #REF! #REF! 8 1 1 8 1.0 1.0

$0.35 $0.19 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 #REF! #REF! 85% #REF! #REF! 34 1 1 34 1.0 1.0

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

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

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

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

$0.00

V Trans Pump Shaft Seal 7001-N0402-02 $0.15

V Trans Pump Housing O-Ring 7001-N0402-08

V Bolt M6x25 7001-N0402-09

V Bolt, Transmission Pump, Long 7001-N0402-13

V Bolt, Transmission Pump, Short 7001-N0402-14

V Bolt Trans Pump Lines 7001-N0402-15

$0.15

$0.08

$0.06

$0.21

$0.02

$0.05

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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

$0.00

$0.00

$0.00

$0.00

$0.00

$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

$2.31 $1.07 $4.24 $0.00 $0.00 $0.00 $0.00 $0.00

$4.24

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Trans Pump Rotor Outer 7001-N0402-04

7001-N0402-04-01

V Trans Pump Gasket

7001-N0402-10

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! -

360 10.00 1.00

88 41.00 1.00

7001-N0402-10 6000 0.60 0.50

V Pump Asm, Transmission 7001-N0402-02

V Trans Pump Rotor Inner and Shaft 7001-N0402-05

Inner 7001-N0402-06

7001-N0402-06-01

Shaft 7001-N0402-07

7001-N0402-07-01

0

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Trans Pump Shaft Seal 7001-N0402-02

6000 0.60 0.50

104 34.73 2.00

400 9.00 1.00

450 8.00 1.00

88 41.00 1.00

450 8.00 1.00

106 34.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

V Trans Pump Shaft Seal 7001-N0402-02

V Trans Pump Housing O-Ring 7001-N0402-08

V Bolt M6x25 7001-N0402-09

V Bolt, Transmission Pump, Long 7001-N0402-13

V Bolt, Transmission Pump, Short 7001-N0402-14

V Bolt Trans Pump Lines 7001-N0402-15

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 4 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Body & Cover 120301-N0602-16 &-17 Part Number: 0701-N0402-16 Weekly Component Volume: Packaging Specification:

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 V Trans Pump, Body 7001-N0402-16 1

Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 360 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.11 $0.03 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.00

3 7001-N0402-16-01 1

Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

CNC Operator CNC Machining, LC, Automatic 

Load 99 2 4 1 0.000 $0.00 $36.98 $40.26 $161.04 $0.00 $0.75 $1.63 $2.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.37 $2.37 $0.00

4 7001-N0402-16-02 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

Heat Treat Operator

229 1.5 1 1 1.066 $0.012 $47.72 $10.17 $10.17 $0.01 $0.31 $0.04 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37 $0.01

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

Mild Hybrid - Start-Stop 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)

4 7001-N0402-16-02 1 Stress Relief Heat Treat @ Bottom. Not Applicable

T5-Al380, SMS

229 1.5 1 1 1.066 $0.012 $47.72 $10.17 $10.17 $0.01 $0.31 $0.04 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37 $0.01

5 7001-N0402-16-03 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-A380, Cast

Mold/Cast/Sinter Operator

Diecast, SMS

480 1 1 1.1 1.066 $1.10 $41.48 $116.73 $128.40 $1.17 $0.09 $0.27 $1.53 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.53 $1.53 $1.17

6 V Trans Pump, Cover 7001-N0402-17 1

Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 360 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.11 $0.03 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.00

7 7001-N0402-17-01 1

Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

CNC Operator

CNC Turning, SS, BF, DA 324 2 4 1 0.000 $0.00 $36.98 $20.48 $81.92 $0.00 $0.23 $0.25 $0.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.48 $0.48 $0.00

8 7001-N0402-17-02 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

Heat Treat Operator

T5-Al380, SMS

420 1.5 1 1 0.358 $0.012 $47.72 $10.17 $10.17 $0.00 $0.17 $0.02 $0.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.20 $0.20 $0.00

9 7001-N0402-17-03 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-A380, Cast

Mold/Cast/Sinter Operator

Diecast, SMS

571 1 1 1.1 0.358 $1.10 $41.48 $116.73 $128.40 $0.39 $0.07 $0.22 $0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.69 $0.69 $0.39

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

$0.00

B Purchase Part - High Impact Item (Full Cost Mapping) $0.00

$0.00

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

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 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub1 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

$1.58

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

Mark-up $5.92

T1 or OEM Total Manufacturing Cost: $1.58 $1.83 $2.50 $5.92 $0.00 $0.00 $0.00 $0.00 $0.00 $5.92

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 Sub3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 4 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Body & Cover 120301-N0602-16 &-17 Part Number: 0701-N0402-16 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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 ----- ----- ----- $0.03 $0.38 $0.35 $0.15 $0.92

Base Cost Impact to Vehicle: $1.58 $1.83 $2.50 $5.92 $0.03 $0.38 $0.35 $0.15 $0.92 $6.83 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $6.83

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 Information

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 4 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Trans Pump, Body 7001-N0402-16

7001-N0402-16-01

7001-N0402-16-02

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 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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

$0.11 $0.03 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0 360 10.00 1.00

$0.75 $1.63 $2.37 $0.00 $0.00 $0.00 $0.00 $0.00 4 CNC workstations, 2 operators/2 work stations, semi-automated load, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 146 1 1 146 1.0 4.0 99 36.38 2.00

$0.31 $0.04 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 3 1,720 27,000 1.0 1.0 229 15.70 1.50

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

7001-N0402-16-02

7001-N0402-16-03

V Trans Pump, Cover 7001-N0402-17

7001-N0402-17-01

7001-N0402-17-02

7001-N0402-17-03

Purchase Part - High Impact Item (Full Cost Mapping)

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)

$0.31 $0.04 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 3 1,720 27,000 1.0 1.0 229 15.70 1.50

$0.09 $0.27 $1.53 $0.00 $0.00 $0.00 $0.00 $0.00 4 Cavity Diecast Tool with Operator Manual Load/Unload Trim Station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 7.50 2 4 30.00 1.1 1.0 480 7.50 1.00

$0.11 $0.03 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 3 1 10 1.0 1.0 360 10.00 1.00

$0.23 $0.25 $0.48 $0.00 $0.00 $0.00 $0.00 $0.00 4 CNC workstations, 2 operators/2 work stations, semi-automated load, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 45 5 1 45 1.0 4.0 324 11.13 2.00

$0.17 $0.02 $0.20 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 3,150 27,000 1.0 1.0 420 8.57 1.50

$0.07 $0.22 $0.69 $0.00 $0.00 $0.00 $0.00 $0.00 4 Cavity Diecast Tool with Operator Manual Load/Unload Trim Station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 6.30 1 4 25.20 1.1 1.0 571 6.30 1.00

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

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

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

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

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

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

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

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.83 $2.50 $5.92 $0.00 $0.00 $0.00 $0.00 $0.00

$5.92

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 4 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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 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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Motor Part Number: 7001-N0402-18 Weekly Component Volume: Packaging Specification:

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

V Gasket, Motor Cover

7001-N0402-30 1

V Gasket, Motor Cover, Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, Terminals

6000 1 1 1 0.084 $0.45 $135.07 $42.91 $42.91 $0.04 $0.02 $0.01 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.04

3 V Shaft, Motor Asm. 7001-N0402-22 1

1 Wash Cycles thru machining T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

CNC Operator

Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.16 $0.16 $0.00

4 7001-N0402-22-01 1 Case Harden T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator Nitriding - Case Harden 281 1 1 1 0.000 $0.00 $47.72 $100.00 $100.00 $0.00 $0.17 $0.36 $0.53 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.53 $0.53 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop 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)

4 7001-N0402-22-01 1 Case Harden @ Bottom. Not Applicable Heat Treat Operator Nitriding - Case Harden 281 1 1 1 0.000 $0.00 $47.72 $100.00 $100.00 $0.00 $0.17 $0.36 $0.53 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.53 $0.53 $0.00

5 7001-N0402-22-02 1

V Shaft Machined T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1040S, Bar

CNC Operator

CNC Turning, SS, BF, DA 77 1 1 1 0.207 $0.80 $36.98 $20.48 $20.48 $0.17 $0.48 $0.27 $0.92 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.92 $0.92 $0.17

6

V Stamped Plate Asm.

7001-N0402-23 26 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS 24000 2 4 1 0.025 $0.75 $42.73 $24.60 $98.40 $0.02 $0.00 $0.00 $0.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.03 $0.68 $0.48

7 7001-N0402-23-01 1 Rotor Stacking T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Elec. Assembly, MC, Base 135 0 4 1 0.000 $0.00 $42.73 $30.00 $120.00 $0.00 $0.00 $0.89 $0.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.89 $0.89 $0.00

8 V Lead, Commutator 7001-N0402-26 12 Stamping T1 Assembly, Mark-up Applied 

@ Bottom.

Copper-Pure, Wire

Cut/Punch/Forming Operator Stamp/Form, XSS 6000 0.5 1 1 0.005 $2.45 $42.73 $24.60 $24.60 $0.01 $0.00 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.24 $0.15

9

V Commutator

7001-N0402-25 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS

128 0.5 1 1 0.024 $3.86 $41.48 $16.39 $16.39 $0.09 $0.16 $0.13 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 $0.38 $0.09

10 V Shaft, Rotor and Commutator 7001-N0402-21 1 Manual Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

164 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.09 $0.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.15 $0.15 $0.00

11

V Rotor Asm., Painted

7001-N0402-20 1

Paint Oven Cure

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

152 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.10 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.16 $0.16 $0.00

12

V Rotor Asm. & Bearings

7001-N0402-19 1 Press Bearings packs on shaft T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

164 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.09 $0.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.15 $0.15 $0.00

13 7001-N0402-19-01 1 Winding Machine T1 Assembly, Mark-up Applied 

@ Bottom. Copper - Windings, <1mm Electromechanical Assembly Elec. Assembly, MHC, Base 199 0.5 3 1 0.159 $2.94 $36.21 $45.00 $135.00 $0.47 $0.09 $0.68 $1.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.24 $1.24 $0.47

14 7001-N0402-19-02 1 Cut grooves T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

CNC Operator

CNC Machining, LMC 240 1 1 1 0.000 $0.00 $36.98 $34.48 $34.48 $0.00 $0.15 $0.14 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00

15

V Trans Pump Motor

7001-N0402-18 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

88 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.11 $0.17 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 $0.28 $0.00

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

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

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

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

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Motor Part Number: 7001-N0402-18 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

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 V Bearing, Motor, Top 7001-N0402-28 1 S $0.00 $0.24 $0.00 $0.24 $0.24

3 V Bearing, Motor, Bottom 7001-N0402-29 1 S $0.00 $0.33 $0.00 $0.33 $0.33

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

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

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

$1.96

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

Mark-up $6.71

T1 or OEM Total Manufacturing Cost: $1.96 $1.53 $3.22 $6.71 $0.00 $0.00 $0.00 $0.00 $0.00 $6.71

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 $0.44 $0.40 $0.17 $1.04

Base Cost Impact to Vehicle: $1.96 $1.53 $3.22 $6.71 $0.03 $0.44 $0.40 $0.17 $1.04 $7.76 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $7.76

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:

3

1

Notes: 

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.

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Motor Part Number: 7001-N0402-18 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Gasket, Motor Cover

7001-N0402-30

V Shaft, Motor Asm. 7001-N0402-22

7001-N0402-22-01

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

$0.02 $0.01 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Single part per hit 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 $0.14 $0.16 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 3 1 10 1.0 1.0

$0.17 $0.36 $0.53 $0.00 $0.00 $0.00 $0.00 $0.00 Nitride 24 Hours @ Approx 600°C, Batches of 13500 Parts 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 6,750 86,400 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

7001-N0402-22-01

7001-N0402-22-02

V Stamped Plate Asm.

7001-N0402-23

7001-N0402-23-01

V Lead, Commutator 7001-N0402-26

V Commutator

7001-N0402-25

V Shaft, Rotor and Commutator 7001-N0402-21

V Rotor Asm., Painted

7001-N0402-20

V Rotor Asm. & Bearings

7001-N0402-19

7001-N0402-19-01

7001-N0402-19-02

V Trans Pump Motor

7001-N0402-18

Purchase Part - High Impact Item (Full Cost Mapping)

$0.17 $0.36 $0.53 $0.00 $0.00 $0.00 $0.00 $0.00 Nitride 24 Hours @ Approx 600°C, Batches of 13500 Parts 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 6,750 86,400 1.0 1.0

$0.48 $0.27 $0.92 $0.00 $0.00 $0.00 $0.00 $0.00 Dual Axis CNC, multi part fixture, bar feed 5 2 10 100 47 4700 96 37.60 85% 113 31.96 47 21 1 47 1.0 1.0

$0.09 $0.11 $0.68 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die in-line with automatic rotor disc stacking equipment. 5 2 10 100 47 4700 2489 1.45 85% 2929 1.23 0.6 2 1 0.6 1.0 4.0

$0.00 $0.89 $0.89 $0.00 $0.00 $0.00 $0.00 $0.00 Rotor stacking equipment, direct feed from stamping press, orientate, stack and press into place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 465 1 1 106.8 1.0 4.0

$0.04 $0.05 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Four parts per hit 5 2 10 100 47 4700 1149 3.13 85% 1352 2.66 0.6 1 4 2.4 1.0 1.0

$0.16 $0.13 $0.38 $0.00 $0.00 $0.00 $0.00 $0.00

Injection mold, 4 cavity, 55 ton

5 2 10 100 47 4700 96 37.60 85% 113 31.96 28.039 1 4 112.16 1.0 1.0

$0.06 $0.09 $0.15 $0.00 $0.00 $0.00 $0.00 $0.00 Low level Assembly - press stamped plate asm to shaft. Glue Commutator in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 22 8 1 22 1.0 1.0

$0.06 $0.10 $0.16 $0.00 $0.00 $0.00 $0.00 $0.00

Batch part, Paint Oven Cure

5 2 10 100 47 4700 96 37.60 85% 113 31.96 71 1 3 71 1.0 1.0

$0.06 $0.09 $0.15 $0.00 $0.00 $0.00 $0.00 $0.00 Press front and rear bearing packs in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 22 2 1 22 1.0 1.0

$0.09 $0.68 $1.24 $0.00 $0.00 $0.00 $0.00 $0.00 Automated winding station, auto load and clamp, cut and position leads. 2.5 2 10 50 47 2350 191 18.80 85% 225 15.98 23 1 1 54.38 1.0 3.0

$0.15 $0.14 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Cut Grooves 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 7 1 15 1.0 1.0

$0.11 $0.17 $0.28 $0.00 $0.00 $0.00 $0.00 $0.00 Place rotor and bearing asm in housing, apply gasket.Place base motor housing asm in place and bolt to 

secure. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 20 1 41 1.0 1.0

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

V Bearing, Motor, Top 7001-N0402-28

V Bearing, Motor, Bottom 7001-N0402-29

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

$0.24

$0.33

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.53 $3.22 $6.71 $0.00 $0.00 $0.00 $0.00 $0.00

$6.71

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Gasket, Motor Cover

7001-N0402-30

V Shaft, Motor Asm. 7001-N0402-22

7001-N0402-22-01

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! -

6000 0.60 1.00

360 10.00 0.25

7001-N0402-22-01 281 12.80 1.00

7001-N0402-22-02

V Stamped Plate Asm.

7001-N0402-23

7001-N0402-23-01

V Lead, Commutator 7001-N0402-26

V Commutator

7001-N0402-25

V Shaft, Rotor and Commutator 7001-N0402-21

V Rotor Asm., Painted

7001-N0402-20

V Rotor Asm. & Bearings

7001-N0402-19

7001-N0402-19-01

7001-N0402-19-02

V Trans Pump Motor

7001-N0402-18

Purchase Part - High Impact Item (Full Cost Mapping)

281 12.80 1.00

77 47.00 1.00

24000 0.15 2.00

135 26.70 -

6000 0.60 0.50

128 28.04 0.50

164 22.00 0.25

152 23.67 0.25

164 22.00 0.25

199 18.13 0.50

240 15.00 1.00

88 41.00 0.25

#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! -

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

V Bearing, Motor, Top 7001-N0402-28

V Bearing, Motor, Bottom 7001-N0402-29

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Housing Asm, Pump Motor Part Number: 7001-N0402-31 Weekly Component Volume: Packaging Specification:

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

V Cover, Motor

7001-N0402-32 1 Plate T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

Plating/Coating Operator Plate/Finish, SMS, MHC

360 2 1 1 0.000 $0.00 $40.84 $125.00 $125.00 $0.00 $0.23 $0.35 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $0.57 $0.00

3 7001-N0402-32-01 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-GSteel-1000S, Coil

Cut/Punch/Forming Operator Stamp/Form, SS

2000 0.5 1 1 2.430 $0.48 $42.73 $42.91 $42.91 $1.17 $0.01 $0.02 $1.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.20 $1.20 $1.17

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

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

Mild Hybrid - Start-Stop 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)

5 V Housing Asm., Pump Motor 7001-N0402-31 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

200 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.05 $0.08 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $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

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

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

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

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

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

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 V Magnet, Pump motor 7001-N0402-33 2 S $0.00 $3.26 $0.00 $6.52 $6.52

3 V Spacer, Magnet, Pump Motor 7001-N0402-34 2 S $0.00 $0.10 $0.00 $0.20 $0.20

4 V Spring Washer, Pump Motor Cover 7001-N0402-35 1 S $0.00 $0.01 $0.00 $0.01 $0.01

5 V Bolt, Cover, Trans Pump 7001-N0402-36 2 S $0.00 $0.02 $0.00 $0.03 $0.03

6 V Screw, Trans Pump Motor Mounting 7001-N0402-37 2 S $0.00 $0.04 $0.00 $0.07 $0.07

7 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 

"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 

Material

$8.00

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

Mark-up $8.73

T1 or OEM Total Manufacturing Cost: $8.00 $0.29 $0.44 $8.73 $0.00 $0.00 $0.00 $0.00 $0.00 $8.73

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.04 $0.57 $0.52 $0.22 $1.35

Base Cost Impact to Vehicle: $8.00 $0.29 $0.44 $8.73 $0.04 $0.57 $0.52 $0.22 $1.35 $10.08 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Housing Asm, Pump Motor Part Number: 7001-N0402-31 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

Net Cost Impact to Vehicle: $10.08

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:

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 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

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:09000064810e7549.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:8/21/2012

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)

V Cover, Motor

7001-N0402-32

7001-N0402-32-01

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

$0.23 $0.35 $0.57 $0.00 $0.00 $0.00 $0.00 $0.00 Zinc plating, batch processed Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 1 10 1.0 1.0

$0.01 $0.02 $1.20 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Single part per hit 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

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

V Housing Asm., Pump Motor 7001-N0402-31

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Magnet, Pump motor 7001-N0402-33

V Spacer, Magnet, Pump Motor 7001-N0402-34

V Spring Washer, Pump Motor Cover 7001-N0402-35

V Bolt, Cover, Trans Pump 7001-N0402-36

V Screw, Trans Pump Motor Mounting 7001-N0402-37

$0.05 $0.08 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Assembly - place magnets, spacers and spring washer in motor cover 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23 12 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 1.0

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

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

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

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

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

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

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

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

$0.00

$6.52

$0.20

$0.01

$0.03

$0.07

$0.00

Mark-up Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.29 $0.44 $8.73 $0.00 $0.00 $0.00 $0.00 $0.00

$8.73

2

Notes: 

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

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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)

V Cover, Motor

7001-N0402-32

7001-N0402-32-01

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! -

360 10.00 2.00

2000 1.80 0.50

#DIV/0! #DIV/0! -

V Housing Asm., Pump Motor 7001-N0402-31

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Magnet, Pump motor 7001-N0402-33

V Spacer, Magnet, Pump Motor 7001-N0402-34

V Spring Washer, Pump Motor Cover 7001-N0402-35

V Bolt, Cover, Trans Pump 7001-N0402-36

V Screw, Trans Pump Motor Mounting 7001-N0402-37

200 18.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Base Motor Asm Part Number: 7001-N0402-38 Weekly Component Volume: Packaging Specification:

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

V Base Motor Asm.

7001-N0402-39 1

Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 360 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.11 $0.03 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.00

3 7001-N0402-39-01 1

Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

CNC Operator

CNC Turning, SS, BF, DA 109 2 4 1 0.000 $0.00 $36.98 $20.48 $81.92 $0.00 $0.68 $0.75 $1.43 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.43 $1.43 $0.00

4 7001-N0402-39-02 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

Heat Treat Operator

644 1.5 1 1 0.291 $0.012 $47.72 $10.17 $10.17 $0.00 $0.11 $0.02 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop 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)

4 7001-N0402-39-02 1 Stress Relief Heat Treat @ Bottom. Not Applicable

T5-Al380, SMS

644 1.5 1 1 0.291 $0.012 $47.72 $10.17 $10.17 $0.00 $0.11 $0.02 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $0.00

5 7001-N0402-39-03 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom.

Aluminum-A380, Cast

Mold/Cast/Sinter Operator

Diecast, SMS

545 1 1 1.1 0.291 $1.10 $41.48 $116.73 $128.40 $0.32 $0.08 $0.24 $0.63 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.63 $0.63 $0.32

6 V Retaining Clip, Brush Asm. To Harness 7001-N0402-42 1

 V Retaining Clip, Brush Asm. 

To Harness 

T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS

9000 0.25 1 1 0.007 $1.76 $41.48 $16.39 $16.39 $0.01 $0.00 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.02 $0.01

7

V Brush Asm., Base

7001-N0402-40 1

V Brush Asm., Base T1 Assembly, Mark-up Applied 

@ Bottom.

PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS

750 0.25 1 1 0.045 $1.46 $41.48 $16.39 $16.39 $0.07 $0.01 $0.02 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.07

8

V Brush & Wire Asm.

7001-N0402-43 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

120 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.08 $0.13 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

9

V Base Motor Asm.

7001-N0402-38 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

103 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.09 $0.15 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $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

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

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

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

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 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 V 6 Terminal Pin 7001-N0402-41 1 S $0.00 $0.10 $0.00 $0.10 $0.10

3 V Magnet, Brush Asm. 7001-N0402-44 2 S $0.00 $0.02 $0.00 $0.04 $0.04

4 V Copper Wire, Brush Asm. 7001-N0402-45 2 S $0.00 $0.01 $0.00 $0.01 $0.01

5 V Spring, Brush Asm. 7001-N0402-46 2 S $0.00 $0.02 $0.00 $0.04 $0.04

6 V Bolt, Brush Asm. to Base 7001-N0402-47 2 S $0.00 $0.02 $0.00 $0.04 $0.04

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.63

"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 

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Base Motor Asm Part Number: 7001-N0402-38 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

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

Mark-up $3.12

T1 or OEM Total Manufacturing Cost: $0.63 $1.16 $1.33 $3.12 $0.00 $0.00 $0.00 $0.00 $0.00 $3.12

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 $0.20 $0.19 $0.08 $0.48

Base Cost Impact to Vehicle: $0.63 $1.16 $1.33 $3.12 $0.02 $0.20 $0.19 $0.08 $0.48 $3.60 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $3.60

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:09000064810e7549.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:8/21/2012

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)

V Base Motor Asm.

7001-N0402-39

7001-N0402-39-01

7001-N0402-39-02

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

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

$0.11 $0.03 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.68 $0.75 $1.43 $0.00 $0.00 $0.00 $0.00 $0.00 4 CNC workstations, 2 operators/2 work stations, semi-automated load, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 132 1 1 132 1.0 4.0

$0.11 $0.02 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 4,830 27,000 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

7001-N0402-39-02

7001-N0402-39-03

V Retaining Clip, Brush Asm. To Harness 7001-N0402-42

V Brush Asm., Base

7001-N0402-40

V Brush & Wire Asm.

7001-N0402-43

V Base Motor Asm.

7001-N0402-38

Purchase Part - High Impact Item (Full Cost Mapping)

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)

$0.11 $0.02 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 4,830 27,000 1.0 1.0

$0.08 $0.24 $0.63 $0.00 $0.00 $0.00 $0.00 $0.00 4 Cavity Diecast Tool with Operator Manual Load/Unload Trim Station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 6.60 1 4 26.40 1.1 1.0

$0.00 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00

Injection mold, 16 Cavity, Box Size 22mm x 21mm x 9mm

5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.4 1 16 6.4 1.0 1.0

$0.01 $0.02 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00

Injection Mold, 4 Cavity , Box Size 60mm x 50mm x 13mm

5 2 10 100 47 4700 96 37.60 85% 113 31.96 4.8 1 4 19.2 1.0 1.0

$0.08 $0.13 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Assembly - place retaining clip onto harness assembly and attached to clips on brush asm. Bolt 

(2) in the motor housing base with apower tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 63 20 1 30 1.0 1.0

$0.09 $0.15 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Assembly - magnet to wire (8sec), spring and magnet/wire asm loaded to base and tabs 

bent(12sec)(pick uphand tool (7 sec)bend tabs to pins(8 sec) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 51 25 1 35 1.0 1.0

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

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

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

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

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

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

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

$0.00

V 6 Terminal Pin 7001-N0402-41

V Magnet, Brush Asm. 7001-N0402-44

V Copper Wire, Brush Asm. 7001-N0402-45

V Spring, Brush Asm. 7001-N0402-46

V Bolt, Brush Asm. to Base 7001-N0402-47

$0.00

$0.10

$0.04

$0.01

$0.04

$0.04

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.16 $1.33 $3.12 $0.00 $0.00 $0.00 $0.00 $0.00

File:09000064810e7549.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:8/21/2012

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

$3.12

2

Notes: 

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

File:09000064810e7549.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:8/21/2012

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)

V Base Motor Asm.

7001-N0402-39

7001-N0402-39-01

7001-N0402-39-02

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

#DIV/0! #DIV/0! -

360 10.00 1.00

109 33.00 2.00

7001-N0402-39-02 644 5.59 1.50

7001-N0402-39-03

V Retaining Clip, Brush Asm. To Harness 7001-N0402-42

V Brush Asm., Base

7001-N0402-40

V Brush & Wire Asm.

7001-N0402-43

V Base Motor Asm.

7001-N0402-38

Purchase Part - High Impact Item (Full Cost Mapping)

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)

644 5.59 1.50

545 6.60 1.00

9000 0.40 0.25

750 4.80 0.25

120 30.00 0.25

103 35.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

V 6 Terminal Pin 7001-N0402-41

V Magnet, Brush Asm. 7001-N0402-44

V Copper Wire, Brush Asm. 7001-N0402-45

V Spring, Brush Asm. 7001-N0402-46

V Bolt, Brush Asm. to Base 7001-N0402-47

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Harness Trans Pump Part Number: 7001-N0402-48 Weekly Component Volume: Packaging Specification:

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

 V Retainer Clip, Connector, Trans. Pump 

Harness 7001-N0402-53 1

 V Retainer Clip, Connector, 

Trans. Pump Harness 

T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS

7200 0.25 1 1 0.003 $1.59 $41.48 $16.39 $16.39 $0.00 $0.00 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.01 $0.00

3

V Cover, Harness, Trans. Pump

7001-N0402-52 1

 V Cover, Harness, Trans. 

Pump, Extrude 

T1 Assembly, Mark-up Applied 

@ Bottom. HDPE BM Grade

Extruding/Drawing Operator Extrusion Molding, NR, SS

896 0.25 1 1 0.008 $0.72 $56.05 $35.94 $35.94 $0.01 $0.02 $0.04 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.01

 V Bracket, Connector, Trans. T1 Assembly, Mark-up Applied 

Cut/Punch/Forming OperatorOEMStamp/Form, Terminals

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

Mild Hybrid - Start-Stop 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)

4 V Bracket, Connector, Trans. Pump Harness 7001-N0402-54 1

 V Bracket, Connector, Trans. 

Pump Harness, Stamp 

T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil OEM 6000 1 1 1 0.015 $0.45 $135.07 $42.91 $42.91 $0.01 $0.02 $0.01 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.04 $0.01

5 V Connector Housing, Trans. Harness 7001-N0402-49 1

 V Connector Housing, Trans. 

Harness, Mold 

T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS

3704 0.25 1 1 0.019 $1.59 $41.48 $16.39 $16.39 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.04 $0.03

6

V Harness, Trans. Pump

7001-N0402-49 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

General Assembly Mech Assembly, LC, Base

200 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.05 $0.08 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $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

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

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

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

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

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 V Wire Asm., Positive 7001-N0402-50 1 S $0.00 $0.50 $0.00 $0.50 $0.50

3 V Wire Asm., Negative 7001-N0402-51 1 S $0.00 $0.50 $0.00 $0.50 $0.50

4 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.

4 0 "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$1.05

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

Mark-up $1.27

T1 or OEM Total Manufacturing Cost: $1.05 $0.09 $0.13 $1.27 $0.00 $0.00 $0.00 $0.00 $0.00 $1.27

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 $0.08 $0.03 $0.20

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

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 

System Description: Moderate 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Harness Trans Pump Part Number: 7001-N0402-48 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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)

Base Cost Impact to Vehicle: $1.05 $0.09 $0.13 $1.27 $0.01 $0.08 $0.08 $0.03 $0.20 $1.46 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $1.46

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:09000064810e7549.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:8/21/2012

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)

 V Retainer Clip, Connector, Trans. Pump 

Harness 7001-N0402-53

V Cover, Harness, Trans. Pump

7001-N0402-52

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 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00

Injection mold, 16 Cavity, Box Size 18mm x 9mm x 9mm

5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.5 1 16 8.0 1.0 1.0

$0.02 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Extrude, Tube 190mmx9.3mm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4.02 1 1 4.02 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

V Bracket, Connector, Trans. Pump Harness 7001-N0402-54

V Connector Housing, Trans. Harness 7001-N0402-49

V Harness, Trans. Pump

7001-N0402-49

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Wire Asm., Positive 7001-N0402-50

V Wire Asm., Negative 7001-N0402-51

$0.02 $0.01 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, Single part per hit 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 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00

Injection mold, 16 Cavity, 45 ton Box Size 18mm x 23mm x 43mm

5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.97 1 16 15.55 1.0 1.0

$0.05 $0.08 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Assembly - place positve & negitive wire asm's in sleeve, then add spacer and connector and 

bracket 5 2 10 100 47 4700 96 37.60 85% 113 31.96 43 16 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 1.0

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

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

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

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

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

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

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

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

$0.00

$0.50

$0.50

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.09 $0.13 $1.27 $0.00 $0.00 $0.00 $0.00 $0.00

$1.27

2

Notes: 

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

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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)

 V Retainer Clip, Connector, Trans. Pump 

Harness 7001-N0402-53

V Cover, Harness, Trans. Pump

7001-N0402-52

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! -

7200 0.50 0.25

896 4.02 0.25

V Bracket, Connector, Trans. Pump Harness 7001-N0402-54

V Connector Housing, Trans. Harness 7001-N0402-49

V Harness, Trans. Pump

7001-N0402-49

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Wire Asm., Positive 7001-N0402-50

V Wire Asm., Negative 7001-N0402-51

6000 0.60 1.00

3704 0.97 0.25

200 18.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Hyd Fitting Part Number: 7001-N0402-55 Weekly Component Volume: Packaging Specification:

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

V Trans Pump Hyd Fitting

7001-N0402-55 1 Assembly T1 Assembly, Mark-up Applied 

@ Bottom. 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 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $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

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

Mild Hybrid - Start-Stop 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)

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

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

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

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

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 V Trans Pump Hyd Fitting Body 7001-N0402-56 1 S $0.00 $0.18 $0.00 $0.18 $0.18

3 V O-Ring Trans Pump Hyd Fitting Thread7001-N0402-57 1 S $0.00 $0.02 $0.00 $0.02 $0.02

4 V O-Ring Trans Pump Hyd Fitting Face 7001-N0402-58 1 S $0.00 $0.02 $0.00 $0.02 $0.02

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.22

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

Mark-up $0.32

T1 or OEM Total Manufacturing Cost: $0.22 $0.04 $0.06 $0.32 $0.00 $0.00 $0.00 $0.00 $0.00 $0.32

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 

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

3

1

Notes: 

a) Items 1,2, & 3 must a

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.02 $0.02 $0.01 $0.05

Base Cost Impact to Vehicle: $0.22 $0.04 $0.06 $0.32 $0.00 $0.02 $0.02 $0.01 $0.05 $0.37 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.37

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810e7549.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:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Trans Pump Hyd Fitting Part Number: 7001-N0402-55 Weekly Component Volume: Packaging Specification:

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

Mild Hybrid - Start-Stop 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:09000064810e7549.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:8/21/2012

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)

V Trans Pump Hyd Fitting

7001-N0402-55

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

$0.04 $0.06 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Assembly - grease fitting and place 2 O rings on ends 5 2 10 100 47 4700 96 37.60 85% 113 31.96 47 13 1 15 1.0 1.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Trans Pump Hyd Fitting Body 7001-N0402-56

V O-Ring Trans Pump Hyd Fitting Thread7001-N0402-57

V O-Ring Trans Pump Hyd Fitting Face 7001-N0402-58

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

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

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

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

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

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

$0.00

$0.18

$0.02

$0.02

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.04 $0.06 $0.32 $0.00 $0.00 $0.00 $0.00 $0.00

$0.32

2

Notes: 

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

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

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)

V Trans Pump Hyd Fitting

7001-N0402-55

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! -

240 15.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

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)

V Trans Pump Hyd Fitting Body 7001-N0402-56

V O-Ring Trans Pump Hyd Fitting Thread7001-N0402-57

V O-Ring Trans Pump Hyd Fitting Face 7001-N0402-58

#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:09000064810e7549.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:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Indented Bill of Materials

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

V Pump Asm, Transmission V Pump Asm, 4.6678 lb Transmission

1 V Trans Pump Body, Washed V Trans Pump 1 # 1.0150 lb

Body

2 V Trans Pump Body, V Trans Pump 1 # 1.0150 lb

Trimmed Body, 

Trimmed

3 V Trans Pump Body, V Trans Pump 1 # 1.0150 lb

Machined Body, 

Machined

4 V Trans Pump Body, Cast V Trans Pump 1 #

Body, Cast

5 V Trans Pump Body, Raw V Trans Pump 1 Aluminum - #

Material Body, Raw #

Material

1 V Trans Pump Shaft Seal V Trans Pump 1 Commodity # 0.0122 lb

Shaft Seal Pricing

1 V Trans Pump Rotor Outer V Trans Pump 1 # 0.0620 lb

Rotor Outer

2 V Trans Pump Rotor Outer, V Trans Pump 1 # 0.0620 lb

Hor. CNC Rotor Outer, 

Hor. CNC

3 V Trans Pump Rotor Outer, V Trans Pump 1 HS150/160 # 0.0620 lb

PM Rotor Outer, 

Raw Material

1 V Trans Pump Rotor Inner V Trans Pump 1 # 0.0790 lb

and Shaft Rotor Inner 

and Shaft

2 V Impellar, Trans Pump V Impellar, 1 Steel - 1060 # 0.0355 lb

Inner, Washed Trans Pump 

Inner

3 V Impellar, Trans Pump V Impellar, 1 Steel - 1060 # 0.0355 lb

Inner, Machined Trans Pump 

Inner, 

Machined

Design Profit®

Page 1 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

V Impellar, Trans Pump Inner, V Impellar, 1 HS150/160 #

Raw Material Trans Pump 

Inner, Raw 
Material

2 V Shafte, Inner Impellar, V Shafte, 1 Steel - 1060 # 0.0435 lb

Trans Pump Inner Impellar, 

Trans Pump

3 V Shafte, Inner Impellar, V Shafte, 1 Steel - 1060 # 0.0435 lb

Trans Pump, Turned Inner Impellar, 

Trans Pump, 

Turned

4 V Shafte, Inner Impellar, Trans V Shafte, Inner 1 Steel - 1060 #

Pump, Raw Material Impellar, Trans 

Pump, Turned, 

Raw 

1 V Trans Pump Housing O-Ring V Trans Pump 1 Commodity # 0.0026 lb

Housing Pricing

O-Ring

1 V Trans Pump Cover, V Trans Pump 1 # 0.3410 lb

Washed Cover

2 V Trans Pump Cover, V Trans Pump 1 # 0.3410 lb

Machined Cover, 

Machined

3 V Trans Pump Cover, V Trans Pump 1 # 0.3410 lb

Trimmed Cover, 

Trimmed

4 V Trans Pump Cover, Cast V Trans Pump 1 #

Cover, Cast

5 V Trans Pump Cover, Raw V Trans Pump 1 Aluminum - #

Material Cover, Raw #

Material

1 V Bolt M6x25 V Bolt M6x25 4 Commodity # 0.0170 lb

Pricing

1 V Trans Pump Gasket V Trans Pump 1 # 0.0175 lb

Gasket

2 V Trans Pump Gasket V Trans Pump 1 PMP Plastic # 0.0175 lb

Gasket, Raw Metal Plastic

Material

1 V Trans Pump Motor Shaft V Trans Pump Motor Shaft V Trans Pump V Trans Pump 1 HS150/160 HS150/160 # 0.0118 lb 0.0118 lb

Interconnect Motor Shaft 

Interconnect

1 V Trans Pump Motor V Trans Pump 1 # 2.8798 lb

Motor

Design Profit®

Page 2 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

V Base Motor Asm. V Base Motor 

Asm.

3 V Base, Motor, Washed V Base, Motor 1 # 0.2773 lb

4 V Base, Motor, Machined V Base, 1 #

Motor, 

Machined

5 V Base, Motor, Trimmed V Base, 1 #

Motor, 

Trimmed

6 V Base, Motor, Cast V Base, 1 #

Motor, Cast

7 V Base, Motor, Cast V Base, Motor, 1 Aluminum - ###
Raw Material #

3 V Harness, Trans. Pump V Harness, 1 # 0.0633 lb

Trans. Pump

4 V Connector Housing, Trans. V Connector 1 PA6 GB6 - #

Harness Housing, GF10

Trans. 

Harness

5 V Connector Housing, Trans. V Connector 1 PA6 GB6 - #

Harness, Raw Mat. Housing, GF10

Trans. 

Harness, Raw 

Mat.

4 V Wire Asm., Positive V Wire Asm., 1 Commodity #

Positive Pricing

4 V Wire Asm., Negative V Wire Asm., 1 Commodity #

Negative Pricing

4 V Cover, Harness, Trans. V Cover, 1 #

Pump Harness, 

Trans. Pump

5 V Cover, Harness, Trans. V Cover, 1 #

Pump Harness, 

Trans. Pump, 

Raw Material

4 V Retainer Clip, Connector, V Retainer 1 #

Trans. Pump Harness Clip, 

Connector, 

Trans. Pump 

Harness

Design Profit®

Page 3 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

V Retainer Clip, Connector, V Retainer PA6 GF15 #

Trans. Pump Harness. Clip, 

Connector, 

Trans. Pump 

Harness, 

4 V Bracket, Connector, Trans. V Bracket, 1 #

Pump Harness Connector, 

Trans. Pump 

Harness

5 V Bracket, Connector, Trans. V Bracket, 1 Steel - 1008 #

Pump Harness Connector, 

Trans. Pump 

Harness. Raw 

Mat

3 V Retaining Clip, Brush Asm. V Retaining 1 # 0.0046 lb

to Harness Clip, Brush 

Asm. to 

Harness

4 V Retaining Clip, Brush Asm. V Retaining 1 PA6 - GF35 #

to Harness, Raw Mat. Clip, Brush 

Asm. to 

Harness Raw 
Materi

3 V Brush Asm. V Brush Asm. 1 # 0.0539 lb

4 V Base, Brush Asm. V Base, Brush 1 #

Asm.

5 V Base, Brush Asm., raw V Base, Brush 1 PBT 30% GF #

Material Asm. Raw 

Material

5 V 6 Terminal Pin V 6 Terminal 1 Commodity #

Pin Pricing

4 V Brush & Wire Asm. V Brush & 1 #

Wire Asm.

5 V Magnet, Brush Asm. V Magnet, 1 Molded #

Brush Asm. Magnet

5 V Copper Wire, Brush Asm. V Copper Wire, 1 Copper #

Brush Asm.

4 V Spring, Brush Asm. V Spring, 1 Commodity #

Brush Asm. Pricing

4 V Brush & Wire Asm. V Brush & 1 #

Wire Asm.

5 V Magnet, Brush Asm. V Magnet, 1 Molded #

Brush Asm. Magnet

Design Profit®

Page 4 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

V Copper Wire, Brush Asm. V Copper Wire, Copper #

Brush Asm.

4 V Spring, Brush Asm. V Spring, 1 Commodity #

Brush Asm. Pricing

3 V Bolt, Brush Asm. to Base V Bolt, Brush 2 Commodity # 0.0054 lb

Asm. to Base Pricing

2 V Rotor Asm. & Bearings V Rotor Asm. 1 # 1.1464 lb

& Bearings

3 M Rotor Asm. M Rotor Asm. 1 # 1.1138 lb

4 M Rotor Asm., Painted M Rotor Asm., 1 #

Painted

5 V Shaft, Rotor and V Shaft, Rotor 1 #

Commutator and 

Commutator

6 V Shaft, Motor Asm. V Shaft, Motor 1 Steel - 1060 #

Asm.

7 V Shaft, Motor Asm., V Shaft, Motor 1 Steel - 1060 ###

Machined Asm., 

Machined

8 V Shaft, Motor Asm., Machined V Shaft, Motor 1 Steel - 1060

Asm., Raw 

Material

6 V Stamped Plate Asm. V Stamped 1 #

Plate Asm.

7 V Plate, Motor, Pump, V Plate, # Steel - 1008 ###

Motor, Pump

8 V Plate, Motor, Pump, Raw V Plate, Motor, 1 Steel - 1008

Material Pump, Raw 

Material
6 V Commutator V 1 #

Commutator

7 V Lead, Commutator V Lead, # Copper ###

Commutator

8 V Lead, Commutator, Raw V Lead, 1 Copper 

Material Commutator, 

Raw Material

7 V Commutator, Raw Material V Commutator, 1 Polyphenylene ###

Raw Material Sulfide (PPS)

4 V Copper Winding, Motor, V Copper 2 Copper #

Pump Winding, 

Motor, Pump

Design Profit®

Page 5 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

3 V Bearing, Motor, Top V Bearing, 1 Commodity 

Motor, Top Pricing

3 V Bearing, Motor, Bottom V Bearing, 1 Commodity # 0.0247 lb

Motor, Bottom Pricing

2 V Gasket, Motor Cover V Gasket, 1 # 0.0076 lb

Motor Cover

3 V Gasket, Motor Cover, Raw V Gasket, 1 PMP Plastic # 0.0076 lb

Material Motor Cover, Metal Plastic

Raw Material

2 V Housing Asm., Pump V Housing 1 # 1.3099 lb

Motor Asm., Pump 

Motor

3 V Cover, Motor V Cover, 1 Galvinized # 0.8579 lb

Motor Steel - G60

4 V Cover, Motor, Raw Material V Cover, 1 Galvinized #

Motor, Raw Steel - G60

Material

3 V Magnet, Pump Motor V Magnet, 2 Commodity # 0.2176 lb

Pump Motor Pricing

3 V Spacer, Magnet, Pump V Spacer, 2 Commodity # 0.0082 lb

Motor Magnet, Pump Pricing

Motor

3 V Spring Washer, Pump Motor V Spring 1 Commodity # 0.0004 lb

Cover Washer, Pump Pricing

Motor Cover

2 V Bolt, Cover, Trans Pump V Bolt, Cover, 2 Commodity # 0.0030 lb

Trans Pump Pricing

1 Screw, Trans Pump Motor V Screw 2 Commodity # 0.0191 lb

Mounting 6mmx25, Pricing

Socket Hd Cap

1 V Trans Pump Hyd Fitting V Trans Pump 1 # 0.1088 lb

Hyd Fitting

2 V Trans Pump Hyd Fitting V Trans Pump 1 Commodity # 0.1080 lb

Body Hyd Fitting Pricing

Body

2 V O-Ring Trans Pump Hyd V O-Ring 1 Commodity # 0.0005 lb

Fitting Thread Trans Pump Pricing

Hyd Fitting 
Thread

2 V O-Ring Trans Pump Hyd V O-Ring 1 Commodity # 0.0003 lb

Fitting Face Trans Pump Pricing

Hyd Fitting 

Face

Design Profit®

Page 6 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

V Trans Pump, External V Trans 1 #

Filter Pump, 

External Filter

2 V Base, External Filter V Base, 1 Galvinized # 0.0295 lb

External Filter Steel - G60

3 V Base, External Filter, V Base, 1 Galvinized # 0.0295 lb

Washed External Steel - G60

Filter, Washed

4 V Base, External Filter, V Base, 1 Galvinized #

Truned External Steel - G60

Filter, Turned

5 V Base, External Filter, Raw V Base, 1 Galvinized #

Material External Filter, Steel - G60

Raw Material

2 V Filter & O-ring Asm. V Filter & 1 # 0.0022 lb

O-ring Asm.

3 V Filter, Pump Asm. V Filter, Pump 1 Commodity # 0.0019 lb

Asm. Pricing

3 V O-Ring, External Filter V O-Ring, 1 SBR # 0.0003 lb

External Filter

0 V Bolt, Transmission Pump, V Bolt, Transmission Pump, V Bolt, V Bolt, 4 Commodity Commodity # 0.0410 lb 0.0410 lb

Long Transmission Pricing

Pump, Long

0 V Trans Pump Line Asm, V Trans Pump 1 # 0.3774 lb

Long Line Asm, 

Long

1 V Tube & Cover Asm. V Tube & 1 Aluminum - # 0.2374 lb

Cover Asm. #

2 V Tube, Trans Line, Long V Tube, Trans 1 Aluminum - # 0.1835 lb

Line, Long #

3 V Tube, Trans Line, Long V Tube, Trans 1 Aluminum - # 0.1835 lb

Line, Long, #

Raw Material

2 V Protective Cover, Tube V Protective 1 Aluminum # 0.0539 lb

Asm. Cover, Tube 

Asm.

3 V Protective Cover, Tube Asm. V Protective 1 Aluminum # 0.0539 lb

Cover, Tube 

Asm., Raw 

Material

1 V Guide, Trans. Line, Long, V Guide, 1 Aluminum - # 0.0685 lb

Washed Trans. Line, #

Long

Design Profit®
Page 7 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

V Guide, Trans. Line, Long, V Guide, Aluminum - 

Machined Trans. Line, #

Long, 

Machined

3 V Guide, Trans. Line, Long, V Guide, 1 Aluminum - # 0.0685 lb

Raw Material Trans. Line, #

Long, Raw 

Material

1 V Guide, Trans. Line, Long V Guide, 1 Aluminum - # 0.0685 lb

Trans. Line, #

Long

2 V Guide, Trans. Line, Long, V Guide, 1 Aluminum - # 0.0685 lb

Machined Trans. Line, #

Long, 

Machined

3 V Guide, Trans. Line, Long, V Guide, 1 Aluminum - # 0.0685 lb

Raw Material Trans. Line, #

Long, Raw 

Material

1 V O-ring, Long Tube Asm. V O-ring, Long 1 Commodity # 0.0015 lb

Tube Asm. Pricing

1 V O-ring, Long Tube Asm. V O-ring, Long 1 Commodity # 0.0015 lb

Tube Asm. Pricing

0 V Bolt Trans Pump Lines V Bolt Trans 1 Commodity # 0.0399 lb

Pump Lines Pricing

0 V Bolt, Transmission Pump, v Bolt, 1 Commodity # 0.0037 lb

Short Transmission Pricing

Pump, Short

0 V Trans Pump Line Asm, V Trans Pump 1 # 0.1514 lb

Short Line Asm, 

Short

1 V Trans Pump Line,Short, V Trans Pump 1 # 0.1493 lb

Asm. Line,Short, 

Asm.

2 V Tube, Trans Line, Short V Tube, Trans 1 Aluminum - # 0.0219 lb

Line, Short 30xx

3 V Tube, Trans Line, Short V Tube, Trans 1 Aluminum - # 0.0219 lb

Line, Short, 30xx

Raw Material

2 V Support Bar, Tube, Short, V Support 1 Aluminum - # 0.0413 lb

Washed Bar, Tube, 30xx

Short

Design Profit®

Page 8 of 9

Copyright 2005© Munro & Associates, Inc.

V Transmission

Level Symbol Name Number Qty Material Piece Cost Weight

3 V Support Bar, Tube, Short, V Support Aluminum - 
Machined Bar, Tube, 30xx

Short, 

Machined

4 V Support Bar, Tube, Short V Support Bar, 1 Aluminum - #

Tube, Short, 30xx

Raw Material

2 V Collar, Tube Asm., Short V Collar, Tube 1 Commodity # 0.0466 lb

Asm., Short Pricing

2 V Metal Seal, Tube, Short V Metal Seal, 1 Commodity # 0.0117 lb

Tube, Short Pricing

2 V Tube End, Washed V Tube End, 1 Aluminum # 0.0278 lb

Washed

3 V Tube End, Machined V Tube End, 1 Aluminum # 0.0278 lb

Machined

4 V Tube End, Machined V Tube End, 1 Aluminum - #

Raw Material 30xx

1 V Foam Seal, Trans Pump V Foam Seal, 1 Commodity # 0.0017 lb

Line Trans Pump Pricing

Line

1 V O-ring, Trans Pump Line V O-ring, Trans 2 Commodity # 0.0002 lb

Pump Line Pricing

0 V Bolt Trans Pump Lines V Bolt Trans 1 Commodity # 0.0399 lb

Pump Lines Pricing

Assembly Totals Report Totals Preassemble

Analyzed Subs:# Piece Cost (Total): #

Unanalyzed Subs: 0

Weight (Total): 5.4441 lb

Parts: #

Fasteners: #

Parts+Unanalyzed: #

Design Profit®

Page 9 of 9

Copyright 2005© Munro & Associates, Inc.
Piece Cost Weight (Total)

(Total)

4.6678 lb 4.6678 lb

1.0150 lb # 1.0150 lb

1.0150 lb # 1.0150 lb

1.0150 lb # 1.0150 lb

1.0150 lb # 1.0150 lb

1.0150 lb # 1.0150 lb

0.0122 lb # 0.0122 lb

0.0620 lb # 0.0620 lb

0.0620 lb # 0.0620 lb

0.0620 lb # 0.0620 lb

0.0790 lb # 0.0790 lb

0.0355 lb # 0.0355 lb

0.0355 lb # 0.0355 lb

Weight Piece Cost Weight (Total)

(Total)

0.0355 lb 0.0355 lb
0.0435 lb # 0.0435 lb

0.0435 lb # 0.0435 lb

0.0435 lb # 0.0435 lb

0.0026 lb # 0.0026 lb

0.3410 lb # 0.3410 lb

0.3410 lb # 0.3410 lb

0.3410 lb # 0.3410 lb

0.3410 lb # 0.3410 lb

0.3410 lb # 0.3410 lb

0.0170 lb # 0.0680 lb

0.0175 lb # 0.0175 lb

0.0175 lb # 0.0175 lb

0.0118 lb # 0.0118 lb

2.8798 lb # 2.8798 lb

Piece Cost Weight (Total)

(Total)

0.4099 lb 0.4099 lb

0.2773 lb # 0.2773 lb

0.2773 lb # 0.2773 lb

0.2773 lb # 0.2773 lb

0.2773 lb # 0.2773 lb

0.2773 lb ## 0.2773 lb
0.0633 lb # 0.0633 lb

0.0142 lb # 0.0142 lb

0.0142 lb # 0.0142 lb

0.0181 lb # 0.0181 lb

0.0181 lb # 0.0181 lb

0.0066 lb # 0.0066 lb

0.0066 lb # 0.0066 lb

0.0015 lb # 0.0015 lb

Weight Piece Cost Weight (Total)

(Total)

0.0015 lb 0.0015 lb

0.0048 lb # 0.0048 lb

0.0048 lb # 0.0048 lb

0.0046 lb # 0.0046 lb

0.0046 lb # 0.0046 lb
0.0539 lb # 0.0539 lb

0.0449 lb # 0.0449 lb

0.0449 lb # 0.0449 lb

0.0000 lb # 0.0000 lb

0.0038 lb # 0.0038 lb

0.0027 lb # 0.0027 lb

0.0011 lb # 0.0011 lb

0.0007 lb # 0.0007 lb

0.0038 lb # 0.0038 lb

0.0027 lb # 0.0027 lb

Weight Piece Cost Weight (Total)

(Total)

0.0011 lb 0.0011 lb

0.0007 lb # 0.0007 lb

0.0054 lb # 0.0108 lb

1.1464 lb # 1.1464 lb

1.1138 lb # 1.1138 lb

0.8063 lb # 0.8063 lb

0.8063 lb # 0.8063 lb

0.0899 lb # 0.0899 lb

0.0899 lb ## 0.0899 lb

# 0.0899 lb # 0.0899 lb

0.6448 lb # 0.6448 lb

0.0248 lb ## 0.6448 lb

# 0.0248 lb # 0.6448 lb
0.0716 lb # 0.0716 lb

0.0023 lb ## 0.0276 lb

# 0.0023 lb # 0.0276 lb

0.0440 lb ## 0.0440 lb

0.0794 lb # 0.1588 lb

Piece Cost Weight (Total)

(Total)

0.0079 lb # 0.0079 lb

0.0247 lb # 0.0247 lb

0.0076 lb # 0.0076 lb

0.0076 lb # 0.0076 lb

1.3099 lb # 1.3099 lb

0.8579 lb # 0.8579 lb

0.8579 lb # 0.8579 lb

0.2176 lb # 0.4352 lb

0.0082 lb # 0.0164 lb

0.0004 lb # 0.0004 lb

0.0030 lb # 0.0060 lb

0.0191 lb # 0.0382 lb

0.1088 lb # 0.1088 lb

0.1080 lb # 0.1080 lb

0.0005 lb # 0.0005 lb
0.0003 lb # 0.0003 lb

Piece Cost Weight (Total)

(Total)

0.0317 lb 0.0317 lb

0.0295 lb # 0.0295 lb

0.0295 lb # 0.0295 lb

0.0295 lb # 0.0295 lb

0.0295 lb # 0.0295 lb

0.0022 lb # 0.0022 lb

0.0019 lb # 0.0019 lb

0.0003 lb # 0.0003 lb

# 0.1640 lb

# 0.3774 lb

0.2374 lb # 0.2374 lb

0.1835 lb # 0.1835 lb

0.1835 lb # 0.1835 lb

0.0539 lb # 0.0539 lb

0.0539 lb # 0.0539 lb

0.0685 lb # 0.0685 lb
Piece Cost Weight (Total)

(Total)

0.0685 lb 0.0685 lb

0.0685 lb # 0.0685 lb

0.0685 lb # 0.0685 lb

0.0685 lb # 0.0685 lb

0.0685 lb # 0.0685 lb

0.0015 lb # 0.0015 lb

0.0015 lb # 0.0015 lb

# 0.0399 lb

# 0.0037 lb

# 0.1514 lb

0.1493 lb # 0.1493 lb

0.0219 lb # 0.0219 lb

0.0219 lb # 0.0219 lb

0.0413 lb # 0.0413 lb

Piece Cost Weight (Total)

(Total)

0.0413 lb # 0.0413 lb
0.0413 lb # 0.0413 lb

0.0466 lb # 0.0466 lb

0.0117 lb # 0.0117 lb

0.0278 lb # 0.0278 lb

0.0278 lb # 0.0278 lb

0.0278 lb # 0.0278 lb

0.0017 lb # 0.0017 lb

0.0002 lb # 0.0004 lb

# 0.0399 lb

Preassembled Totals

Analyzed Subs:

Unanalyzed Subs:

Parts:

Fasteners:

Parts+Unanalyzed:
Assembly Report

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$0.00 Tool V Transmission First Fixture 0.0000 sec 0.0000 sec

$35.51 Subassembly V Transmission V Pump Asm, Transmission V Pump Asm, 9.0000 sec 9.0000 sec

Transmission

$35.51 Tool V Pump Asm, First Fixture 0.0000 sec 0.0000 sec

Transmission

$20.81 P.-P. Part V Pump Asm, V Trans Pump Body, Washed V Trans Pump 4.0000 sec 4.0000 sec

Transmission Body

$20.81 Tool V Trans Pump Washer, In'Line Special 0.0000 sec 0.0000 sec

Body, Washed Dedicated

$28.18 P.-P. Part V Trans Pump V Trans Pump Body, Trimmed V Trans Pump 0.0000 sec 0.0000 sec

Body, Washed Body, Trimmed

$28.18 Tool V Trans Pump First Fixture 0.0000 sec 0.0000 sec

Body, Trimmed

$43.52 P.-P. Part V Trans Pump V Trans Pump Body, Machined V Trans Pump 0.0000 sec 0.0000 sec

Body, Trimmed Body, Machined

$43.52 Tool V Trans Pump Trim Press 0.0000 sec 0.0000 sec

Body, Machined

##### P.-P. Part V Trans Pump V Trans Pump Body, Cast V Trans Pump 0.0000 sec 7.0000 sec

Body, Machined Body, Cast

##### Tool V Trans Pump Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec

Body, Cast

##### Part V Trans Pump V Trans Pump Body, Raw V Trans Pump 0.0000 sec 7.4600 sec

Body, Cast Material Body, Raw 

Material

- - - Raw Material Req 1.066 lbs Raw Material Req 1.066 lbs - - -

- - - 4 Cavity Mold - - -

- - - Box Size 5.7" L x 3.2" W x 2.3" H - - -

$28.18 Operation V Trans Pump Load Part 3.0000 sec 3.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Clamp Part 3.0000 sec 3.0000 sec

Body, Trimmed

- - - Front Face, (two flanges turned - - -

up)

$28.18 Material Mod. V Trans Pump Mill Flat Med 4.0000 sec 4.0000 sec

Body, Trimmed

Design Profit ®

Page 1 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec

Body, Trimmed
- - - inner hole - - -

$28.18 Operation V Trans Pump CDI 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec

Body, Trimmed

- - - outer hole - - -

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump CDI 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Body, Trimmed

- - - Bottom Side, With 4 tapped holes - - -

$28.18 Material Mod. V Trans Pump Mill Flat Med 4.0000 sec 4.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump CDI 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Cut Groove Large 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Chamfer ID Lrg 2.0000 sec 2.0000 sec

Body, Trimmed

Design Profit ®

Page 2 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$28.18 Operation V Trans Pump CDI 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec

Body, Trimmed

- - - Drilling operation for small hole at - - -

an angle 

$28.18 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Body, Trimmed

- - - Position part for machining on - - -

flanges

$28.18 Material Mod. V Trans Pump Mill Face 2.0000 sec 2.0000 sec
Body, Trimmed

$28.18 Operation V Trans Pump CDI 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump CDI 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Body, Trimmed

- - - Position Part for maching fitting - - -

location

$28.18 Material Mod. V Trans Pump Spot Face 0.5000 sec 0.5000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Drill Hole 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Body, Trimmed

$28.18 Material Mod. V Trans Pump Tap Hole 4.0000 sec 4.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Unclamp Part 1.0000 sec 1.0000 sec

Body, Trimmed

$28.18 Operation V Trans Pump Remove Part 2.0000 sec 2.0000 sec

Body, Trimmed

$20.81 Operation V Trans Pump Load Part 3.0000 sec 3.0000 sec

Body, Washed

Design Profit ®

Page 3 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.81 Operation V Trans Pump Wash Part Medium 5.0000 sec 5.0000 sec

Body, Washed

$20.81 Operation V Trans Pump Unload Part 2.0000 sec 2.0000 sec

Body, Washed

- - - 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 - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 4 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 Part V Pump Asm, V Trans Pump Shaft Seal V Trans Pump 4.0000 sec 4.0000 sec

Transmission Shaft Seal

$35.51 Tool V Pump Asm, Special Tool 6.0000 sec 6.0000 sec

Transmission

$35.51 Fastening V Pump Asm, Press Together 3.0000 sec 3.0000 sec

Transmission

$35.51 Operation V Pump Asm, Part Manipulation 3.0000 sec 3.0000 sec

Transmission

$10.75 P.-P. Part V Pump Asm, V Trans Pump Rotor Outer V Trans Pump 5.0000 sec 5.0000 sec

Transmission Rotor Outer

$10.75 Tool V Trans Pump Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec

Rotor Outer DRY

$47.77 P.-P. Part V Trans Pump V Trans Pump Rotor Outer, Hor. V Trans Pump 0.0000 sec 0.0000 sec

Rotor Outer CNC Rotor Outer, Hor. 

CNC

$47.77 Tool V Trans Pump EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec

Rotor Outer, Hor. Machine

CNC

$47.77 Part V Trans Pump V Trans Pump Rotor Outer, PM V Trans Pump 0.0000 sec 0.0000 sec
Rotor Outer, Hor. Rotor Outer, Raw 

CNC Material

- - - HS150/160, PM part - - -

$47.77 Operation V Trans Pump Load Part 3.0000 sec 3.0000 sec

Rotor Outer, Hor. 

CNC

Design Profit ®

Page 5 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$47.77 Material Mod. V Trans Pump Polish Surface small 10.0000 sec10.0000 sec

Rotor Outer, Hor. 

CNC

- - - Polish top face - - -

$47.77 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Rotor Outer, Hor. 

CNC

$47.77 Material Mod. V Trans Pump Polish Surface small 10.0000 sec10.0000 sec

Rotor Outer, Hor. 

CNC

- - - Polish Bottom Face - - -

$47.77 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Rotor Outer, Hor. 

CNC

$47.77 Material Mod. V Trans Pump Polish Surface small 10.0000 sec10.0000 sec

Rotor Outer, Hor. 

CNC

- - - Polish Outer Rim Polish Outer Rim - - -

$47.77 Operation V Trans Pump Unload Part 2.0000 sec 2.0000 sec

Rotor Outer, Hor. 

CNC

$10.75 Operation V Trans Pump Load Part 3.0000 sec 3.0000 sec

Rotor Outer

$10.75 Operation V Trans Pump Wash Part Medium 5.0000 sec 5.0000 sec

Rotor Outer

$10.75 Operation V Trans Pump Unload Part 2.0000 sec 2.0000 sec

Rotor Outer

$29.69 Subassembly V Pump Asm, V Trans Pump Rotor Inner and V Trans Pump 9.0000 sec 9.0000 sec

Transmission Shaft Rotor Inner and 

Shaft

$29.69 Tool V Trans Pump Press 0.0000 sec 0.0000 sec

Rotor Inner and 

Shaft

$20.81 P.-P. Part V Trans Pump V Impellar, Trans Pump Inner, V Impellar, Trans 3.0000 sec 3.0000 sec

Rotor Inner and Washed Pump Inner

Shaft

$20.81 Tool V Impellar, Trans Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec

Pump Inner, DRY

Washed

$35.42 P.-P. Part V Impellar, Trans V Impellar, Trans Pump Inner, V Impellar, Trans 0.0000 sec 0.0000 sec

Pump Inner, Machined Pump Inner, 

Washed Machined

Design Profit ®
Page 6 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$35.42 Tool V Impellar, Trans EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec

Pump Inner, Machine

Machined

$35.42 Part V Impellar, Trans V Impellar, Trans Pump Inner, V Impellar, Trans 0.0000 sec 0.0000 sec

Pump Inner, Raw Material Pump Inner, Raw 

Machined Material

- - - HS150/160 - - -

$35.42 Operation V Impellar, Trans Load Part 3.0000 sec 3.0000 sec

Pump Inner, 

Machined

$35.42 Material Mod. V Impellar, Trans Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec

Pump Inner, 

Machined

$35.42 Operation V Impellar, Trans Auto Tool Change 5.0000 sec 5.0000 sec

Pump Inner, 

Machined

$35.42 Material Mod. V Impellar, Trans Polish Surface small 10.0000 sec10.0000 sec

Pump Inner, 

Machined

- - - Polish top face - - -

$35.42 Operation V Impellar, Trans Part Manipulation 3.0000 sec 3.0000 sec

Pump Inner, 

Machined

$35.42 Material Mod. V Impellar, Trans Polish Surface small 10.0000 sec10.0000 sec

Pump Inner, 

Machined

- - - Polish Bottom Face - - -

$35.42 Operation Operation V Impellar, Trans V Impellar, Trans Unload Part Unload Part 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec

Pump Inner, 

Machined

$20.81 Operation V Impellar, Trans Load Part 3.0000 sec 3.0000 sec

Pump Inner, 

Washed

$20.81 Operation V Impellar, Trans Wash Part Medium 5.0000 sec 5.0000 sec

Pump Inner, 

Washed

$20.81 Operation V Impellar, Trans Unload Part 2.0000 sec 2.0000 sec

Pump Inner, 

Washed

$10.75 P.-P. Part V Trans Pump V Shafte, Inner Impellar, Trans V Shafte, Inner 3.0000 sec 3.0000 sec

Rotor Inner and Pump Impellar, Trans 

Shaft Pump

Design Profit ®

Page 7 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$10.75 Tool V Shafte, Inner Washer Turbo Tunnel 0.0000 sec 0.0000 sec

Impellar, Trans 
Pump

$20.90 P.-P. Part V Shafte, Inner V Shafte, Inner Impellar, Trans V Shafte, Inner 0.0000 sec 0.0000 sec

Impellar, Trans Pump, Turned Impellar, Trans 

Pump Pump, Turned

$20.90 Tool V Shafte, Inner CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec

Impellar, Trans bar

Pump, Turned

- - - Includes Bar Feeder - - -

$20.90 Part V Shafte, Inner V Shafte, Inner Impellar, Trans V Shafte, Inner 0.0000 sec 0.0000 sec

Impellar, Trans Pump, Raw Material Impellar, Trans 

Pump, Turned Pump, Turned, 

Raw 

- - - 0.50in bar stock, 1060 steel - - -

- - - est.3,211mm3 of material= - - -

0.0557lbs.

- - - 0.0557lb.@65cents/lb= $0.0362 - - -

- - - Bar stock weight 0.0557 lbs. - - -

- - - Box size of finished part 10Dmm - - -

40Lmm

$20.90 Operation V Shafte, Inner Load Part 3.0000 sec 3.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Material Mod. V Shafte, Inner Turn end face 1-30mm 2.0000 sec 2.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Operation V Shafte, Inner Auto Tool Change 5.0000 sec 5.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Material Mod. V Shafte, Inner Turn OD 30-60mm 2.0000 sec 2.0000 sec

Impellar, Trans 

Pump, Turned

- - - this turning poration is for the - - -

length of the bar

$20.90 Operation V Shafte, Inner CDI 1.0000 sec 1.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Material Mod. V Shafte, Inner Turn OD 1-30mm 1.0000 sec 1.0000 sec

Impellar, Trans 

Pump, Turned

- - - End that mates with motor - - -

Design Profit ®

Page 8 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.90 Operation V Shafte, Inner Auto Tool Change 5.0000 sec 5.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Material Mod. V Shafte, Inner Cut to Length 1.0000 sec 1.0000 sec

Impellar, Trans 

Pump, Turned

- - - After part is cut-off it needs to be - - -

relaoded 

$20.90 Operation V Shafte, Inner Load Part 3.0000 sec 3.0000 sec

Impellar, Trans 

Pump, Turned
$20.90 Material Mod. V Shafte, Inner Drill Hole 1.0000 sec 1.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Operation V Shafte, Inner Auto Tool Change 5.0000 sec 5.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Material Mod. V Shafte, Inner Mill Face 2.0000 sec 2.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Operation V Shafte, Inner Part Manipulation 3.0000 sec 3.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Material Mod. V Shafte, Inner Mill Face 2.0000 sec 2.0000 sec

Impellar, Trans 

Pump, Turned

$20.90 Operation V Shafte, Inner Auto Tool Change 5.0000 sec 5.0000 sec

Impellar, Trans 

Pump, Turned

$10.75 Operation V Shafte, Inner Load Part 3.0000 sec 3.0000 sec

Impellar, Trans 

Pump

$10.75 Operation V Shafte, Inner Wash Part Medium 5.0000 sec 5.0000 sec

Impellar, Trans 

Pump

$10.75 Operation V Shafte, Inner Unload Part 2.0000 sec 2.0000 sec

Impellar, Trans 

Pump

$29.69 Fastening V Trans Pump Press Together 3.0000 sec 3.0000 sec

Rotor Inner and 

Shaft

$35.51 Operation V Pump Asm, Align to Outer Impellar 3.0000 sec 3.0000 sec

Transmission

Design Profit ®

Page 9 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$35.51 Part V Pump Asm, V Trans Pump Housing O-Ring V Trans Pump 8.0000 sec 8.0000 sec

Transmission Housing O-Ring

$20.81 P.-P. Part V Pump Asm, V Trans Pump Cover, Washed V Trans Pump 7.0000 sec 7.0000 sec

Transmission Cover

$20.81 Tool V Trans Pump Washer Turbo Tunnel 0.0000 sec 0.0000 sec

Cover, Washed

$21.43 P.-P. Part V Trans Pump V Trans Pump Cover, Machined V Trans Pump 0.0000 sec 0.0000 sec

Cover, Washed Cover, Machined

$21.43 Tool V Trans Pump CNC Turning 2 Axis SL-10, Odd 0.0000 sec 0.0000 sec

Cover, Machined Form

$43.52 P.-P. Part V Trans Pump V Trans Pump Cover, Trimmed V Trans Pump 0.0000 sec 0.0000 sec

Cover, Machined Cover, Trimmed

$43.52 Tool V Trans Pump Trim Press 0.0000 sec 0.0000 sec

Cover, Trimmed

$70.80 P.-P. Part V Trans Pump V Trans Pump Cover, Cast V Trans Pump 0.0000 sec 6.6600 sec

Cover, Trimmed Cover, Cast

$70.80 Tool V Trans Pump Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec

Cover, Cast

$70.80 Part V Trans Pump V Trans Pump Cover, Raw V Trans Pump 0.0000 sec 6.3000 sec
Cover, Cast Material Cover, Raw 

Material

- - - Raw Material Req 0.358 lbs - - -

- - - 4 Cavity Mold - - -

- - - Box Size 3.5" L x 4.35" W x 1.5" - - -

H

$21.43 Operation V Trans Pump Load Part 3.0000 sec 3.0000 sec

Cover, Machined

$21.43 Operation V Trans Pump Clamp Part 3.0000 sec 3.0000 sec

Cover, Machined

- - - Front Face, flat side - - -

$21.43 Material Mod. V Trans Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec

Cover, Machined

$21.43 Operation V Trans Pump Unclamp Part 1.0000 sec 1.0000 sec

Cover, Machined

$21.43 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Cover, Machined

$21.43 Operation V Trans Pump Clamp Part 3.0000 sec 3.0000 sec

Cover, Machined

- - - Side with 2 boos' - - -

$21.43 Material Mod. V Trans Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec

Cover, Machined

Design Profit ®

Page 10 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$21.43 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Cover, Machined

$21.43 Material Mod. Material Mod. V Trans Pump V Trans Pump Drill Hole 1-30mm Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec

Cover, Machined

$21.43 Operation V Trans Pump CDI 1.0000 sec 1.0000 sec

Cover, Machined

$21.43 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Cover, Machined

$21.43 Material Mod. V Trans Pump Drill & Chamfer Hole 30-60mm 2.0000 sec 2.0000 sec

Cover, Machined

- - - Large hole - - -

$21.43 Operation V Trans Pump Auto Tool Change 5.0000 sec 5.0000 sec

Cover, Machined

$21.43 Material Mod. V Trans Pump Tap Hole 0.5000 sec 0.5000 sec

Cover, Machined

$21.43 Operation V Trans Pump Unclamp Part 1.0000 sec 1.0000 sec

Cover, Machined

$21.43 Operation V Trans Pump Remove Part 2.0000 sec 2.0000 sec

Cover, Machined

$20.81 Operation V Trans Pump Load Part 3.0000 sec 3.0000 sec

Cover, Washed

$20.81 Operation V Trans Pump Wash Part Medium 5.0000 sec 5.0000 sec

Cover, Washed

$20.81 Operation V Trans Pump Remove Part 2.0000 sec 2.0000 sec

Cover, Washed

$35.51 Part V Pump Asm, V Bolt M6x25 V Bolt M6x25 2.0000 sec 2.0000 sec

Transmission

$35.51 Tool V Pump Asm, 4 Spindle Nut Runner 6.0000 sec 6.0000 sec
Transmission

$35.51 Fastening V Pump Asm, Power Screw 4.0000 sec 4.0000 sec

Transmission

$35.51 Operation V Pump Asm, Part Manipulation 3.0000 sec 3.0000 sec

Transmission

- - - Space for Printing - - -

- - - Space for Printing - - -

$15.50 P.-P. Part V Pump Asm, V Trans Pump Gasket V Trans Pump 6.0000 sec 6.0000 sec

Transmission Gasket

$15.50 Tool V Trans Pump Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec

Gasket

Design Profit ®

Page 11 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$15.50 Part V Trans Pump V Trans Pump Gasket V Trans Pump 0.0000 sec 0.6000 sec

Gasket Gasket, Raw 

Material

- - - Material: PMP Plastic Metal - - -

Plastic

- - - Blank weight 0.097 lbs - - -

- - - Press Size 25 Ton Progressive - - -

Die 

- - - Part Size after stamping (82L by - - -

105W by 1.0H)mm

$35.51 Part V Pump Asm, V Trans Pump Motor Shaft V Trans Pump 3.0000 sec 3.0000 sec

Transmission Interconnect Motor Shaft 

Interconnect

- - - 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 - - -

$29.69 Subassembly V Pump Asm, V Trans Pump Motor V Trans Pump 9.0000 sec 9.0000 sec

Transmission Motor

$29.69 Tool V Trans Pump First Fixture 0.0000 sec 0.0000 sec

Motor

$29.69 Subassembly V Trans Pump V Base Motor Asm. V Base Motor 6.0000 sec 6.0000 sec

Motor Asm.
$29.69 Tool V Base Motor First Fixture 0.0000 sec 0.0000 sec

Asm.

Design Profit ®

Page 12 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.81 P.-P. Part V Base Motor V Base, Motor, Washed V Base, Motor 3.0000 sec 3.0000 sec

Asm.

$20.81 Tool V Base, Motor, Washer Turbo Tunnel 0.0000 sec 0.0000 sec

Washed

$21.43 P.-P. Part V Base, Motor, V Base, Motor, Machined V Base, Motor, 0.0000 sec 3.0000 sec

Washed Machined

$21.43 Tool V Base, Motor, CNC Turning 2 Axis SL-10, Odd 0.0000 sec 0.0000 sec

Machined Form

$43.52 P.-P. Part V Base, Motor, V Base, Motor, Trimmed V Base, Motor, 0.0000 sec 0.0000 sec

Machined Trimmed

$43.52 Tool V Base, Motor, Trim Press 0.0000 sec 0.0000 sec

Trimmed

$70.80 P.-P. Part V Base, Motor, V Base, Motor, Cast V Base, Motor, 0.0000 sec 6.7500 sec

Trimmed Cast

$70.80 Tool V Base, Motor, Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec

Cast

$70.80 Part V Base, Motor, V Base, Motor, Cast V Base, Motor, 0.0000 sec 6.5900 sec

Cast Raw Material

- - - Raw Material Req 0.29117 lbs - - -

- - - 4 Cavity Mold - - -

- - - Box Size 3.5" L x 4.0" W x 1.065" - - -

H

$21.43 Operation V Base, Motor, Load Part 3.0000 sec 3.0000 sec

Machined

$21.43 Operation V Base, Motor, Clamp Part 3.0000 sec 3.0000 sec

Machined

- - - Front Face, flat with single boss - - -

$21.43 Material Mod. V Base, Motor, Turn End Face 60-100mm 6.0000 sec 6.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Turn OD 1-30mm 1.0000 sec 1.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Turn end face 1-30mm 2.0000 sec 2.0000 sec

Machined

- - - this turning includes the side and - - -

face of th boss

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

Design Profit ®

Page 13 of #

Copyright 2005© Munro & Associates, Inc.
V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

- - - Two differnt sizes of drilled and - - -

tapped holes

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

- - - smaller hole - - -

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

- - - larger hole - - -

$21.43 Operation V Base, Motor, Unclamp Part 1.0000 sec 1.0000 sec

Machined

$21.43 Operation V Base, Motor, Part Manipulation 3.0000 sec 3.0000 sec

Machined

$21.43 Operation V Base, Motor, Clamp Part 3.0000 sec 3.0000 sec

Machined

- - - Inner face, the face is the sunken - - -

in one

$21.43 Material Mod. Material Mod. V Base, Motor, V Base, Motor, Turn End Face 60-100mm Turn End Face 60-100mm 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Turn OD Med 60-100mm 3.0000 sec 3.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Turn End Face 60-100mm 6.0000 sec 6.0000 sec

Machined

Design Profit ®

Page 14 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Turn End Face 30-60mm 4.0000 sec 4.0000 sec

Machined

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec
Machined

$21.43 Material Mod. V Base, Motor, Chamfer ID 1.0000 sec 1.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

- - - These two holes are small and - - -

next to the lg holes

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, End Mill 1.0000 sec 1.0000 sec

Machined

- - - end mill was for tiny boss, - - -

locating feature

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Turn OD 1-30mm 1.0000 sec 1.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Chamfer ID Lrg 2.0000 sec 2.0000 sec

Machined

- - - Chamfer and turning for center - - -

hole

$21.43 Operation V Base, Motor, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$21.43 Material Mod. V Base, Motor, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec

Machined

$21.43 Operation V Base, Motor, CDI 1.0000 sec 1.0000 sec

Machined

- - - these holes were on the side - - -

$21.43 Operation V Base, Motor, Unclamp Part 1.0000 sec 1.0000 sec

Machined

$21.43 Operation Operation V Base, Motor, V Base, Motor, Remove Part Remove Part 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec

Machined

Design Profit ®

Page 15 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.81 Operation V Base, Motor, Load Part 3.0000 sec 3.0000 sec

Washed

$20.81 Operation V Base, Motor, Wash Part Medium 5.0000 sec 5.0000 sec

Washed

$20.81 Operation V Base, Motor, Remove Part 2.0000 sec 2.0000 sec

Washed

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

$29.69 Subassembly V Base Motor V Harness, Trans. Pump V Harness, 4.0000 sec 4.0000 sec

Asm. Trans. Pump

$29.69 Tool V Harness, First Fixture 0.0000 sec 0.0000 sec

Trans. Pump

$16.39 P.-P. Part V Harness, V Connector Housing, Trans. V Connector 3.0000 sec 3.0000 sec
Trans. Pump Harness Housing, Trans. 

Harness

$16.39 Tool V Connector Injection Molding Machine 55-150 0.0000 sec 0.0000 sec

Housing, Trans. ton

Harness

$16.39 Part V Connector V Connector Housing, Trans. V Connector 0.0000 sec 0.9720 sec

Housing, Trans. Harness, Raw Mat. Housing, Trans. 

Harness Harness, Raw 

Mat.

- - - Material: PA6-GF10...Used $/lb of - - -

PA6-GF15

- - - Raw Material Req 0.0190 lbs - - -

from Cost Sheet

- - - 16 Cavity Mold, 45 ton - - -

- - - Box Size 23mm L x 18mm W x - - -

43mm H

$29.69 Part V Harness, V Wire Asm., Positive V Wire Asm., 6.0000 sec 6.0000 sec

Trans. Pump Positive

$29.69 Part V Harness, V Wire Asm., Negative V Wire Asm., 6.0000 sec 6.0000 sec

Trans. Pump Negative

$29.69 Fastening V Harness, Push In Place 2.0000 sec 2.0000 sec

Trans. Pump

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 16 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$35.94 P.-P. Part V Harness, V Cover, Harness, Trans. Pump V Cover, 3.0000 sec 3.0000 sec

Trans. Pump Harness, Trans. 

Pump

$35.94 Tool V Cover, Extruder 32mm Base 0.0000 sec 0.0000 sec

Harness, Trans. 

Pump

$35.94 Part V Cover, V Cover, Harness, Trans. Pump V Cover, 0.0000 sec 4.0200 sec

Harness, Trans. Harness, Trans. 

Pump Pump, Raw 

Material

- - - HDPE - - -

- - - Box Size 190mmL x 9.3mmW x - - -

9.3mmH

$29.69 Fastening V Harness, Push In Place 2.0000 sec 2.0000 sec

Trans. Pump

$29.69 Operation V Harness, CDI 1.0000 sec 1.0000 sec

Trans. Pump

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

$16.39 P.-P. Part V Harness, V Retainer Clip, Connector, V Retainer Clip, 4.0000 sec 4.0000 sec

Trans. Pump Trans. Pump Harness Connector, 

Trans. Pump 

Harness
$16.39 Tool V Retainer Clip, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec

Connector, ton

Trans. Pump 

Harness

$16.39 Part V Retainer Clip, V Retainer Clip, Connector, V Retainer Clip, 0.0000 sec 0.5050 sec

Connector, Trans. Pump Harness. Connector, 

Trans. Pump Trans. Pump 

Harness Harness, 

- - - PA6 GF15 - - -

- - - Raw Material Req 0.003 lbs from - - -

Cost Sheet

- - - 16 Cavity Mold - - -

- - - Box Size 9mm L x 18mm W x - - -

9mm H

$29.69 Tool V Harness, Hand Tool 3.0000 sec 3.0000 sec

Trans. Pump

Design Profit ®

Page 17 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$29.69 Fastening V Harness, Push In Place 2.0000 sec 2.0000 sec

Trans. Pump

$29.69 Operation V Harness, CDI 1.0000 sec 1.0000 sec

Trans. Pump

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

$15.50 P.-P. Part V Harness, V Bracket, Connector, Trans. V Bracket, 3.0000 sec 3.0000 sec

Trans. Pump Pump Harness Connector, 

Trans. Pump 

Harness

$15.50 Tool V Bracket, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec

Connector, 

Trans. Pump 

Harness

$15.50 Part V Bracket, V Bracket, Connector, Trans. V Bracket, 0.0000 sec 0.6000 sec

Connector, Pump Harness Connector, 

Trans. Pump Trans. Pump 

Harness Harness. Raw 

Mat

- - - Material, 1008 sheet steel - - -

- - - Blank weight 0.015 lbs - - -

- - - Press Size 25 Ton & Progressive - - -

Die

- - - Part Size after stamping (27L by - - -

20W by 13H)mm

$29.69 Tool V Harness, Hand Tool 3.0000 sec 3.0000 sec

Trans. Pump

$29.69 Fastening V Harness, Push In Place 2.0000 sec 2.0000 sec

Trans. Pump
- - - Wires are pressed through the - - -

holes in the housing

$29.69 Fastening V Base Motor Push Wire In 3.0000 sec 3.0000 sec

Asm.

$29.69 Operation V Base Motor CDI 1.0000 sec 1.0000 sec

Asm.

Design Profit ®

Page 18 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$16.39 P.-P. Part V Base Motor V Retaining Clip, Brush Asm. to V Retaining Clip, 6.0000 sec 6.0000 sec

Asm. Harness Brush Asm. to 

Harness

$16.39 Tool V Retaining Clip, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec

Brush Asm. to ton

Harness

$16.39 Part V Retaining Clip, V Retaining Clip, Brush Asm. to V Retaining Clip, 0.0000 sec 0.4090 sec

Brush Asm. to Harness, Raw Mat. Brush Asm. to 

Harness Harness Raw 

Materi

- - - Material: PA6 GF35 - - -

- - - Raw Material Req 0.007 lbs from - - -

Cost Sheet

- - - 16 Cavity Mold - - -

- - - Box Size 22mm L x 21mm W x - - -

9mm H

$29.69 Multitouch Multitouch V Base Motor V Base Motor Regrab W Regrab Wire Regrab W Regrab Wire 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec

Asm.

$29.69 Fastening V Base Motor Push in Electrical Connector 2.0000 sec 2.0000 sec

Asm.

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

$29.69 Subassembly V Base Motor V Brush Asm. V Brush Asm. 6.0000 sec 6.0000 sec

Asm.

$29.69 Tool V Brush Asm. First Fixture 0.0000 sec 0.0000 sec

$16.39 Subassembly V Brush Asm. V Base, Brush Asm. V Base, Brush 3.0000 sec 3.0000 sec

Asm.

$16.39 Tool V Base, Brush Injection Molding Machine 55-150 0.0000 sec 0.0000 sec

Asm. ton

$16.39 Part V Base, Brush V Base, Brush Asm., raw Material V Base, Brush 0.0000 sec 2.8200 sec

Asm. Asm. Raw 

Material

$16.39 Part V Base, Brush V 6 Terminal Pin V 6 Terminal Pin 2.0000 sec 2.0000 sec

Asm.

- - - 0.100 lbs. taken out of PBT in - - -

sheet for terminals

- - - Raw Material Req 0.045 lbs from - - -

Cost Sheet

- - - 4 Cavity Mold - - -
Design Profit ®

Page 19 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - Box Size 60mm L x 50mm W x - - -

13mm H

$43.52 Subassembly V Brush Asm. V Brush & Wire Asm. V Brush & Wire 5.0000 sec 5.0000 sec

Asm.

$43.52 Tool V Brush & Wire Magnet Machine 0.0000 sec 0.0000 sec

Asm.

$43.52 Part V Brush & Wire V Magnet, Brush Asm. V Magnet, Brush 4.0000 sec 4.0000 sec

Asm. Asm.

- - - Used $xxxxx/lb for magnet - - -

Material

$43.52 Part V Brush & Wire V Copper Wire, Brush Asm. V Copper Wire, 2.0000 sec 2.0000 sec

Asm. Brush Asm.

- - - Used $2.45/lb for Copper - - -

- - - Wire is formed in the magnet - - -

$29.69 Tool V Brush Asm. Hand Tool 3.0000 sec 3.0000 sec

$29.69 Material Mod. V Brush Asm. Bend Tab 3.0000 sec 3.0000 sec

- - - Wire is captured under bent tab - - -

$29.69 Part V Brush Asm. V Spring, Brush Asm. V Spring, Brush 5.0000 sec 5.0000 sec

Asm.

$29.69 Operation V Brush Asm. Press Spring Down 2.0000 sec 2.0000 sec

$29.69 Tool V Brush Asm. Hand Tool 3.0000 sec 3.0000 sec

$29.69 Material Mod. V Brush Asm. Bend Tab 3.0000 sec 3.0000 sec

- - - Bent tab retains spring and brush - - -

$43.52 Subassembly V Brush Asm. V Brush & Wire Asm. V Brush & Wire 5.0000 sec 5.0000 sec

Asm.

$43.52 Tool V Brush & Wire Magnet Machine 0.0000 sec 0.0000 sec

Asm.

- - - DO NOT USE WRONG - - -

MATERIAL

$43.52 Part V Brush & Wire V Magnet, Brush Asm. V Magnet, Brush 4.0000 sec 4.0000 sec

Asm. Asm.

- - - Used $XXXX/lb for magnet - - -

Material

$43.52 Part V Brush & Wire V Copper Wire, Brush Asm. V Copper Wire, 2.0000 sec 2.0000 sec

Asm. Brush Asm.

- - - Used $2.45/lb for Copper - - -

- - - Wire is formed in the magnet - - -

$29.69 Tool V Brush Asm. Hand Tool 3.0000 sec 3.0000 sec

$29.69 Material Mod. V Brush Asm. Bend Tab 3.0000 sec 3.0000 sec

Design Profit ®

Page 20 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score
- - - Wire is captured under bent tab - - -

$29.69 Part V Brush Asm. V Spring, Brush Asm. V Spring, Brush 5.0000 sec 5.0000 sec

Asm.

$29.69 Operation V Brush Asm. Press Spring Down 2.0000 sec 2.0000 sec

$29.69 Tool V Brush Asm. Hand Tool 3.0000 sec 3.0000 sec

$29.69 Material Mod. V Brush Asm. Bend Tab 3.0000 sec 3.0000 sec

- - - Bent tab retains spring and brush - - -

$29.69 Fastening V Base Motor Push in Electrical Connector 2.0000 sec 2.0000 sec

Asm.

$29.69 Operation V Base Motor CDI 1.0000 sec 1.0000 sec

Asm.

$29.69 Operation V Base Motor Align to Base 2.0000 sec 2.0000 sec

Asm.

$29.69 Part V Base Motor V Bolt, Brush Asm. to Base V Bolt, Brush 2.0000 sec 2.0000 sec

Asm. Asm. to Base

$29.69 Tool V Base Motor Power Tool 4.0000 sec 4.0000 sec

Asm.

$29.69 Fastening V Base Motor Power Screw 4.0000 sec 4.0000 sec

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 - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 21 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 - - -

$29.69 Subassembly V Trans Pump V Rotor Asm. & Bearings V Rotor Asm. & 4.0000 sec 4.0000 sec

Motor Bearings

$29.69 Tool V Rotor Asm. & Press 0.0000 sec 0.0000 sec

Bearings

$29.69 Subassembly V Rotor Asm. & M Rotor Asm. M Rotor Asm. 3.0000 sec 3.0000 sec

Bearings

$29.69 Tool M Rotor Asm. First Fixture 0.0000 sec 0.0000 sec

$55.17 Subassembly M Rotor Asm. M Rotor Asm., Painted M Rotor Asm., 3.0000 sec 3.0000 sec

Painted

$55.17 Tool M Rotor Asm., First Fixture 0.0000 sec 0.0000 sec

Painted

- - - Spray or dipped (e-coat) Keep - - -

this NOTE

- - - Add Part & Delete note, Pick Cost - - -

Cnt that apply's

$29.69 Subassembly M Rotor Asm., V Shaft, Rotor and Commutator V Shaft, Rotor 2.0000 sec 2.0000 sec

Painted and Commutator

$29.69 Tool V Shaft, Rotor Press 0.0000 sec 0.0000 sec

and Commutator

$10.75 P.-P. Part V Shaft, Rotor V Shaft, Motor Asm. V Shaft, Motor 3.0000 sec 3.0000 sec

and Commutator Asm.

Design Profit ®

Page 22 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$10.75 Tool V Shaft, Motor Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec

Asm. DRY

$20.90 P.-P. Part V Shaft, Motor V Shaft, Motor Asm., Machined V Shaft, Motor 0.0000 sec 0.0000 sec

Asm. Asm., Machined

$20.90 Tool V Shaft, Motor CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec

Asm., Machined bar

$20.90 Part V Shaft, Motor V Shaft, Motor Asm., Machined V Shaft, Motor 0.0000 sec 0.0000 sec

Asm., Machined Asm., Raw 

Material

- - - Includes Bar Feeder - - -

- - - 0.5" bar stock, 1060 steel - - -

- - - 0.2073@65cents/lb= $0.1347 - - -

- - - Bar stock weight 0.2073 lbs. - - -

- - - Box size of finished part D9mm x - - -

L95mm

$20.90 Operation V Shaft, Motor Load Part 3.0000 sec 3.0000 sec

Asm., Machined

$20.90 Material Mod. V Shaft, Motor Turn end face 1-30mm 2.0000 sec 2.0000 sec

Asm., Machined

$20.90 Operation V Shaft, Motor Auto Tool Change 5.0000 sec 5.0000 sec

Asm., Machined

$20.90 Material Mod. V Shaft, Motor Turn OD 30-60mm 2.0000 sec 2.0000 sec
Asm., Machined

$20.90 Operation V Shaft, Motor CDI 1.0000 sec 1.0000 sec

Asm., Machined

$20.90 Material Mod. V Shaft, Motor Turn OD 1-30mm 1.0000 sec 1.0000 sec

Asm., Machined

- - - round end - - -

$20.90 Operation V Shaft, Motor CDI 1.0000 sec 1.0000 sec

Asm., Machined

$20.90 Material Mod. V Shaft, Motor Turn OD 1-30mm 1.0000 sec 1.0000 sec

Asm., Machined

- - - End that mates with motor - - -

$20.90 Operation V Shaft, Motor Auto Tool Change 5.0000 sec 5.0000 sec

Asm., Machined

$20.90 Material Mod. V Shaft, Motor Cut to Length 1.0000 sec 1.0000 sec

Asm., Machined

- - - After part is cut-off it needs to be - - -

relaoded 

$20.90 Operation V Shaft, Motor Load Part 3.0000 sec 3.0000 sec

Asm., Machined

Design Profit ®

Page 23 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.90 Material Mod. V Shaft, Motor Drill Hole 1.0000 sec 1.0000 sec

Asm., Machined

$20.90 Operation V Shaft, Motor Auto Tool Change 5.0000 sec 5.0000 sec

Asm., Machined

$20.90 Material Mod. V Shaft, Motor Mill Face 2.0000 sec 2.0000 sec

Asm., Machined

$20.90 Operation V Shaft, Motor Part Manipulation 3.0000 sec 3.0000 sec

Asm., Machined

$20.90 Material Mod. V Shaft, Motor Mill Face 2.0000 sec 2.0000 sec

Asm., Machined

$20.90 Operation V Shaft, Motor Auto Tool Change 5.0000 sec 5.0000 sec

Asm., Machined

- - - Knurl four grooves for stator - - -

retention

$20.90 Material Mod. V Shaft, Motor Turn Threads 2.0000 sec 2.0000 sec

Asm., Machined

$20.90 Operation V Shaft, Motor Unload Part 2.0000 sec 2.0000 sec

Asm., Machined

$10.75 Operation V Shaft, Motor Load Part 3.0000 sec 3.0000 sec

Asm.

$10.75 Operation V Shaft, Motor Wash Part Medium 5.0000 sec 5.0000 sec

Asm.

$10.75 Operation V Shaft, Motor Unload Part 2.0000 sec 2.0000 sec

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 - - -

Design Profit ®

Page 24 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 - - -

$29.69 Subassembly V Shaft, Rotor V Stamped Plate Asm. V Stamped Plate 3.0000 sec 3.0000 sec

and Commutator Asm.

$29.69 Tool V Stamped Plate First Fixture 0.0000 sec 0.0000 sec

Asm.

- - - 26 Plates, 1.00mm thick - - -

$15.50 P.-P. Part V Stamped Plate V Plate, Motor, Pump, V Plate, Motor, 3.0000 sec 3.0000 sec

Asm. Pump

$15.50 Tool V Plate, Motor, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec

Pump, 

$15.50 Part V Plate, Motor, V Plate, Motor, Pump, Raw V Plate, Motor, 0.0000 sec 0.6000 sec

Pump, Material Pump, Raw 

Material

- - - Input actual time from cost model - - -

in symbol

- - - Put Material Used In Part Symbol - - -

- - - Add Notes for the following - - -

- - - Blank weight 0.0248 lbs - - -

- - - Press Size 25 Ton Progressive - - -

Die

- - - Part Size after stamping (55L by - - -

55W by 1.2H)mm

$29.69 Tool V Stamped Plate Special Tool 0.0000 sec 0.0000 sec

Asm.

Design Profit ®
Page 25 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$29.69 Operation V Stamped Plate Lock stack to mandrel 3.0000 sec 3.0000 sec

Asm.

$29.69 Operation V Stamped Plate Unload Part 2.0000 sec 2.0000 sec

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 - - -

$29.69 Fastening V Shaft, Rotor Press Together 3.0000 sec 3.0000 sec

and Commutator

$29.69 Tool V Shaft, Rotor Glue Bottle 3.0000 sec 3.0000 sec

and Commutator

$29.69 Operation V Shaft, Rotor Apply RTV 2.0000 sec 2.0000 sec

and Commutator

- - - The glue holds the Commutator - - -

in place

$16.39 P.-P. Part V Shaft, Rotor V Commutator V Commutator 5.0000 sec 5.0000 sec

and Commutator

$16.39 Tool V Commutator Injection Molding Machine 55-150 0.0000 sec 0.0000 sec

ton

$15.50 P.-P. Part V Commutator V Lead, Commutator V Lead, 0.0000 sec 0.0000 sec

Commutator

$15.50 Tool V Lead, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec

Commutator

$15.50 Part V Lead, V Lead, Commutator, Raw V Lead, 0.0000 sec 0.6000 sec

Commutator Material Commutator, 

Raw Material

- - - Blank weight 0.005lbs - - -

- - - Press Size 25 Ton & Type of - - -

Press 

- - - Part Size after stamping (18 L by - - -

6 W by 9 H)mm

- - - 1 stack or 12 parts inserted into - - -

tool? 

$16.39 Tool V Commutator Insertion Tool 0.0000 sec 0.0000 sec

Design Profit ®

Page 26 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$16.39 Operation V Commutator Insulator Insertion 0.5000 sec 0.5000 sec

$16.39 Part V Commutator V Commutator, Raw Material V Commutator, 0.0000 sec 28.0390 sec
Raw Material

- - - Raw Material Req 0.024 lbs from - - -

Cost Sheet

- - - 4 Cavity Mold - - -

- - - Box Size 22mm L x 22mm W x - - -

22mm H

$29.69 Fastening V Shaft, Rotor Press Together 3.0000 sec 3.0000 sec

and Commutator

$55.17 Operation M Rotor Asm., Load Part 3.0000 sec 3.0000 sec

Painted

$55.17 Operation M Rotor Asm., Paint Part Small 3.0000 sec 3.0000 sec

Painted

$55.17 Tool M Rotor Asm., Oven 0.0000 sec 0.0000 sec

Painted

$55.17 Operation M Rotor Asm., Paint Oven Cure 60.0000 sec60.0000 sec

Painted

$55.17 Operation M Rotor Asm., Unload Part 2.0000 sec 2.0000 sec

Painted

- - - 6 pole, 24 winds per pole, 2 - - -

phases (12 poles)

- - - 5'4" -19.5 gauge (0.031") - - -

varnished copper wire

$29.69 Tool M Rotor Asm. Wire Winding Machine 0.0000 sec 0.0000 sec

$29.69 Operation M Rotor Asm. Load Part 3.0000 sec 3.0000 sec

$29.69 Part M Rotor Asm. V Copper Winding, Motor, Pump V Copper 7.0000 sec 7.0000 sec

Winding, Motor, 

Pump

$29.69 Operation M Rotor Asm. Wind Stator 30.0000 sec30.0000 sec

- - - No Solder is used on the - - -

commutator

$29.69 Tool M Rotor Asm. Crimping Tool 4.0000 sec 4.0000 sec

$29.69 Fastening M Rotor Asm. Crimp tabs 1.0000 sec 1.0000 sec

$29.69 Operation M Rotor Asm. CDI 1.0000 sec 1.0000 sec

$29.69 Operation M Rotor Asm. Unload Part 2.0000 sec 2.0000 sec

- - - Test Rotor Assembly Test Rotor Assembly - - -

$29.69 Operation M Rotor Asm. Load Part 3.0000 sec 3.0000 sec

$29.69 Inspect M Rotor Asm. Test Stator Assembly 30.0000 sec30.0000 sec

Design Profit ®

Page 27 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$29.69 Operation M Rotor Asm. Unload Part 2.0000 sec 2.0000 sec

- - - Balancing Operation - - -

$29.69 Operation M Rotor Asm. Spin Balance 10.0000 sec10.0000 sec

$29.69 Operation M Rotor Asm. Auto Tool Change 5.0000 sec 5.0000 sec

$29.69 Material Mod. M Rotor Asm. Cut Groove sml 2.0000 sec 2.0000 sec

$29.69 Operation M Rotor Asm. CDI 1.0000 sec 1.0000 sec

- - - Verify Balancing - - -

$29.69 Operation M Rotor Asm. Spin Balance 10.0000 sec10.0000 sec

$29.69 Operation M Rotor Asm. Unclamp Part 1.0000 sec 1.0000 sec

$29.69 Operation M Rotor Asm. Unload Part 2.0000 sec 2.0000 sec

$29.69 Part V Rotor Asm. & V Bearing, Motor, Top V Bearing, Motor, 6.0000 sec 6.0000 sec
Bearings Top

- - - Cost estimated in Bearing - - -

Calculator

$29.69 Fastening V Rotor Asm. & Press Together 3.0000 sec 3.0000 sec

Bearings

$29.69 Operation V Rotor Asm. & Part Manipulation 3.0000 sec 3.0000 sec

Bearings

$29.69 Part V Rotor Asm. & V Bearing, Motor, Bottom V Bearing, Motor, 4.0000 sec 4.0000 sec

Bearings Bottom

$29.69 Fastening V Rotor Asm. & Press Together 3.0000 sec 3.0000 sec

Bearings

- - - Cost estimated in Bearing - - -

Calculator

- - - 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 - - -

Design Profit ®

Page 28 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 - - -

$15.50 P.-P. Part V Trans Pump V Gasket, Motor Cover V Gasket, Motor 6.0000 sec 6.0000 sec

Motor Cover

$15.50 Tool V Gasket, Motor Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec

Cover
$15.50 Part V Gasket, Motor V Gasket, Motor Cover, Raw V Gasket, Motor 0.0000 sec 0.6000 sec

Cover Material Cover, Raw 

Material

- - - Material: PMP plastic, Metal, - - -

Plastic: gasket

- - - Blank weight 0.084 lbs - - -

- - - Press Size 25 Ton Prog. Die - - -

- - - Part Size after stamping (105L by - - -

105W by 1.0 H)mm

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 29 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$29.69 Operation V Trans Pump Align Gasket 3.0000 sec 3.0000 sec

Motor

$29.69 Subassembly V Trans Pump V Housing Asm., Pump Motor V Housing Asm., 6.0000 sec 6.0000 sec

Motor Pump Motor

$29.69 Tool V Housing Asm., First Fixture 0.0000 sec 0.0000 sec

Pump Motor

$42.91 P.-P. Part V Housing Asm., V Cover, Motor V Cover, Motor 3.0000 sec 3.0000 sec

Pump Motor

$42.91 Tool V Cover, Motor Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec

$42.91 Part V Cover, Motor V Cover, Motor, Raw Material V Cover, Motor, 0.0000 sec 1.8000 sec

Raw Material

- - - Galvanized G60 - - -

- - - Blank weight 2.43 lbs - - -

- - - Press Size 300 Ton Prog. Die - - -

- - - Part Size after stamping (90L by - - -

103W by 77H)mm

- - - Zinc Coated - - -

$29.69 Part V Housing Asm., V Magnet, Pump Motor V Magnet, Pump 4.0000 sec 4.0000 sec

Pump Motor Motor

- - - Used $7.50/lb for magnet - - -

Material

$29.69 Fastening V Housing Asm., Set In Place 1.0000 sec 1.0000 sec

Pump Motor

$29.69 Part V Housing Asm., V Spacer, Magnet, Pump Motor V Spacer, 1.0000 sec 1.0000 sec

Pump Motor Magnet, Pump 

Motor

$29.69 Tool V Housing Asm., Hand Tool 3.0000 sec 3.0000 sec

Pump Motor

$29.69 Fastening V Housing Asm., Push In Place 2.0000 sec 2.0000 sec

Pump Motor

$29.69 Part V Housing Asm., V Spring Washer, Pump Motor V Spring Washer, 2.0000 sec 2.0000 sec

Pump Motor Cover Pump Motor 

Cover
$29.69 Fastening V Housing Asm., Set In Place 1.0000 sec 1.0000 sec

Pump Motor

$29.69 Part V Trans Pump V Bolt, Cover, Trans Pump V Bolt, Cover, 2.0000 sec 2.0000 sec

Motor Trans Pump

$29.69 Tool V Trans Pump Power Tool 4.0000 sec 4.0000 sec

Motor

$29.69 Fastening V Trans Pump Power Screw 4.0000 sec 4.0000 sec

Motor

Design Profit ®

Page 30 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$35.51 Part V Pump Asm, Screw, Trans Pump Motor V Screw 2.0000 sec 2.0000 sec

Transmission Mounting 6mmx25, Socket 

Hd Cap

$35.51 Tool V Pump Asm, 2 Spindle Allen Screw Driver 6.0000 sec 6.0000 sec

Transmission

$35.51 Fastening V Pump Asm, Power Screw 4.0000 sec 4.0000 sec

Transmission

- - - 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 - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 31 of #
Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 32 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

$35.51 Subassembly V Pump Asm, V Trans Pump Hyd Fitting V Trans Pump 7.0000 sec 7.0000 sec

Transmission Hyd Fitting

Design Profit ®

Page 33 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$35.51 Tool V Trans Pump First Fixture 0.0000 sec 0.0000 sec

Hyd Fitting

$35.51 Part V Trans Pump V Trans Pump Hyd Fitting Body V Trans Pump 2.0000 sec 2.0000 sec

Hyd Fitting Hyd Fitting Body

$35.51 Tool V Trans Pump GREASE 6.0000 sec 6.0000 sec

Hyd Fitting

$35.51 Part V Trans Pump V O-Ring Trans Pump Hyd Fitting V O-Ring Trans 6.0000 sec 6.0000 sec

Hyd Fitting Thread Pump Hyd Fitting 

Thread

$35.51 Operation V Trans Pump Lubricate O-Ring 3.0000 sec 3.0000 sec

Hyd Fitting

$35.51 Tool V Trans Pump O-Ring Assembly Tool 3.0000 sec 3.0000 sec

Hyd Fitting

$35.51 Fastening V Trans Pump PUSH ON 2.0000 sec 2.0000 sec

Hyd Fitting

$35.51 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Hyd Fitting

$35.51 Tool V Trans Pump GREASE 6.0000 sec 6.0000 sec
Hyd Fitting

$35.51 Part V Trans Pump V O-Ring Trans Pump Hyd Fitting V O-Ring Trans 8.0000 sec 8.0000 sec

Hyd Fitting Face Pump Hyd Fitting 

Face

$35.51 Operation V Trans Pump Lubricate O-Ring 3.0000 sec 3.0000 sec

Hyd Fitting

$35.51 Tool V Trans Pump O-Ring Assembly Tool 3.0000 sec 3.0000 sec

Hyd Fitting

$35.51 Fastening V Trans Pump PUSH ON 2.0000 sec 2.0000 sec

Hyd Fitting

$35.51 Tool V Pump Asm, Power Tool 4.0000 sec 4.0000 sec

Transmission

$35.51 Fastening V Pump Asm, Power Screw 4.0000 sec 4.0000 sec

Transmission

$35.51 Subassembly V Pump Asm, V Trans Pump, External Filter V Trans Pump, 10.0000 sec10.0000 sec

Transmission External Filter

$35.51 Tool V Trans Pump, First Fixture 0.0000 sec 0.0000 sec

External Filter

$55.17 P.-P. Part V Trans Pump, V Base, External Filter V Base, External 2.0000 sec 2.0000 sec

External Filter Filter

$55.17 Tool V Base, External Anodizing Equipment 0.0000 sec 0.0000 sec

Filter

- - - Zinc Plating, Batched Processed - - -

Design Profit ®

Page 34 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$55.17 Operation Operation V Base, External V Base, External Load Part Load Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec

Filter

$10.75 P.-P. Part V Base, External V Base, External Filter, Washed V Base, External 2.0000 sec 2.0000 sec

Filter Filter, Washed

$10.75 Tool V Base, External Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec

Filter, Washed DRY

$20.90 P.-P. Part V Base, External V Base, External Filter, Truned V Base, External 0.0000 sec 0.0000 sec

Filter, Washed Filter, Turned

$20.90 Tool V Base, External CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec

Filter, Truned bar

$20.90 Part V Base, External V Base, External Filter, Raw V Base, External 0.0000 sec 0.0000 sec

Filter, Truned Material Filter, Raw 

Material

- - - Includes Bar Feeder - - -

- - - 0.750" Bar Stock - - -

- - - Bar stock weight 0.186 lbs. - - -

- - - Box size of finished part 19Dmm - - -

x 21Lmm

$20.90 Operation V Base, External Load Part 3.0000 sec 3.0000 sec

Filter, Truned

$20.90 Material Mod. V Base, External Turn end face 1-30mm 2.0000 sec 2.0000 sec

Filter, Truned

$20.90 Operation V Base, External CDI 1.0000 sec 1.0000 sec

Filter, Truned

$20.90 Material Mod. V Base, External Turn OD 1-30mm 1.0000 sec 1.0000 sec

Filter, Truned
$20.90 Operation V Base, External Auto Tool Change 5.0000 sec 5.0000 sec

Filter, Truned

$20.90 Material Mod. V Base, External Turn Face Contoured 5.0000 sec 5.0000 sec

Filter, Truned

$20.90 Operation V Base, External CDI 1.0000 sec 1.0000 sec

Filter, Truned

$20.90 Material Mod. V Base, External Turn Face Contoured 5.0000 sec 5.0000 sec

Filter, Truned

$20.90 Operation V Base, External Auto Tool Change 5.0000 sec 5.0000 sec

Filter, Truned

$20.90 Material Mod. V Base, External Drill Hole 1.0000 sec 1.0000 sec

Filter, Truned

$20.90 Operation V Base, External Part Manipulation 3.0000 sec 3.0000 sec

Filter, Truned

Design Profit ®

Page 35 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.90 Material Mod. V Base, External Drill Hole 1.0000 sec 1.0000 sec

Filter, Truned

$20.90 Operation V Base, External Auto Tool Change 5.0000 sec 5.0000 sec

Filter, Truned

$20.90 Material Mod. V Base, External Cut to Length 1.0000 sec 1.0000 sec

Filter, Truned

$20.90 Operation V Base, External Unload Part 2.0000 sec 2.0000 sec

Filter, Truned

$10.75 Operation V Base, External Load Part 3.0000 sec 3.0000 sec

Filter, Washed

$10.75 Operation V Base, External Wash Part Medium 5.0000 sec 5.0000 sec

Filter, Washed

$10.75 Operation V Base, External Unload Part 2.0000 sec 2.0000 sec

Filter, Washed

- - - 3.33914 sq. inches of surface - - -

plating

$55.17 Operation V Base, External Electroplate Process 1.0104 sec 1.8156 sec

Filter

$55.17 Operation V Base, External Remove Part 2.0000 sec 2.0000 sec

Filter

$35.51 Tool V Trans Pump, Hand Tool 3.0000 sec 3.0000 sec

External Filter

$35.51 Fastening V Trans Pump, Push In Place 2.0000 sec 2.0000 sec

External Filter

$35.51 Subassembly V Trans Pump, V Filter & O-ring Asm. V Filter & O-ring 4.0000 sec 4.0000 sec

External Filter Asm.

$35.51 Tool V Filter & O-ring First Fixture 0.0000 sec 0.0000 sec

Asm.

$35.51 Part V Filter & O-ring V Filter, Pump Asm. V Filter, Pump 4.0000 sec 4.0000 sec

Asm. Asm.

$35.51 Part V Filter & O-ring V O-Ring, External Filter V O-Ring, 3.0000 sec 3.0000 sec

Asm. External Filter

$35.51 Tool V Filter & O-ring Hand Tool 3.0000 sec 3.0000 sec

Asm.

$35.51 Operation V Filter & O-ring Set O-ring in Place 2.0000 sec 2.0000 sec
Asm.

$35.51 Fastening V Trans Pump, Push In Place 2.0000 sec 2.0000 sec

External Filter

$35.51 Tool V Pump Asm, Special Tool 6.0000 sec 6.0000 sec

Transmission

$35.51 Fastening V Pump Asm, Press Together 3.0000 sec 3.0000 sec

Transmission

Design Profit ®

Page 36 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$0.00 Part V Transmission V Bolt, Transmission Pump, Long V Bolt, 7.0000 sec 7.0000 sec

Transmission 

Pump, Long

$0.00 Tool V Transmission 4 Spindle Nut Runner 6.0000 sec 6.0000 sec

$0.00 Fastening V Transmission Power Screw 4.0000 sec 4.0000 sec

$0.00 Operation V Transmission CDI 1.0000 sec 1.0000 sec

- - - Long line connects Aux trans - - -

pump to trans

$44.85 Subassembly V Transmission V Trans Pump Line Asm, Long V Trans Pump 4.0000 sec 4.0000 sec

Line Asm, Long

$44.85 Tool V Trans Pump Tube Bending Equipment 0.0000 sec 0.0000 sec

Line Asm, Long

$44.96 Subassembly V Trans Pump V Tube & Cover Asm. V Tube & Cover 3.0000 sec 3.0000 sec

Line Asm, Long Asm.

$44.96 Tool V Tube & Cover Projection Welder 3.0000 sec 3.0000 sec

Asm.

$44.85 P.-P. Part V Tube & Cover V Tube, Trans Line, Long V Tube, Trans 6.0000 sec 6.0000 sec

Asm. Line, Long

$44.85 Tool V Tube, Trans Tube Bending Equipment 0.0000 sec 0.0000 sec

Line, Long

$44.85 Part V Tube, Trans V Tube, Trans Line, Long V Tube, Trans 6.0000 sec 6.0000 sec

Line, Long Line, Long, Raw 

Material

- - - Aluminum $1.10/lbx0.0219= - - -

$0.02

$44.85 Operation V Tube, Trans Clamp Part 3.0000 sec 3.0000 sec

Line, Long

$44.85 Material Mod. V Tube, Trans Cut to Length 1.0000 sec 1.0000 sec

Line, Long

$44.85 Operation V Tube, Trans Unclamp Part 1.0000 sec 1.0000 sec

Line, Long

$44.85 Operation V Tube, Trans Clamp Part 3.0000 sec 3.0000 sec

Line, Long

$44.85 Material Mod. V Tube, Trans Bend Tube 1.0000 sec 1.0000 sec

Line, Long

$44.85 Operation V Tube, Trans Unclamp Part 1.0000 sec 1.0000 sec

Line, Long

$44.85 Operation V Tube, Trans Part Manipulation 3.0000 sec 3.0000 sec

Line, Long

$44.85 Operation V Tube, Trans Clamp Part 3.0000 sec 3.0000 sec

Line, Long

Design Profit ®
Page 37 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$44.85 Operation V Tube, Trans Unclamp Part 1.0000 sec 1.0000 sec

Line, Long

- - - 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 - - -

$0.00 P.-P. Part V Tube & Cover V Protective Cover, Tube Asm. V Protective 6.0000 sec 6.0000 sec

Asm. Cover, Tube 

Asm.

$0.00 Tool V Protective Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec

Cover, Tube 

Asm.

$0.00 Part V Protective V Protective Cover, Tube Asm. V Protective 0.0000 sec 0.6000 sec

Cover, Tube Cover, Tube 

Asm. Asm., Raw 

Material

- - - Blank weight 0.125 lbs - - -

- - - Press Size 25 Ton Porgressive - - -

Die

- - - Part Size after stamping ( 60L by - - -

46 W by 33 H)mm

$44.96 Operation V Tube & Cover Clamp Part 3.0000 sec 3.0000 sec

Asm.

$44.96 Material Mod. V Tube & Cover Spot Weld 3.0000 sec 3.0000 sec

Asm.

$44.96 Operation V Tube & Cover Unclamp Part 1.0000 sec 1.0000 sec

Asm.

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 38 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 - - -

$20.81 P.-P. Part V Trans Pump V Guide, Trans. Line, Long, V Guide, Trans. 3.0000 sec 3.0000 sec

Line Asm, Long Washed Line, Long

$20.81 Tool V Guide, Trans. Washer Turbo Tunnel 0.0000 sec 0.0000 sec

Line, Long, 

Washed

$31.33 P.-P. Part V Guide, Trans. V Guide, Trans. Line, Long, V Guide, Trans. 0.0000 sec 0.0000 sec

Line, Long, Machined Line, Long, 

Washed Machined

$31.33 Tool V Guide, Trans. EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec

Line, Long, Machine

Machined

$31.33 Part V Guide, Trans. V Guide, Trans. Line, Long, Raw V Guide, Trans. 0.0000 sec 0.0000 sec

Line, Long, Material Line, Long, Raw 

Machined Material

- - - Aluminum bar stock 1.0" x 0.5" - - -

- - - 0.1067 lbs. Blank weight - - -

- - - Aluminum $1.10/lbx0.1067= - - -

$0.12

$31.33 Operation V Guide, Trans. Load Part 3.0000 sec 3.0000 sec

Line, Long, 

Machined

- - - Small hole and small spot face - - -

$31.33 Material Mod. Material Mod. V Guide, Trans. V Guide, Trans. Drill Hole Drill Hole 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec

Line, Long, 

Machined

Design Profit ®

Page 39 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Spot Face 0.5000 sec 0.5000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

- - - Large Hole and Large Spot face - - -

$31.33 Material Mod. V Guide, Trans. Drill Hole 1.0000 sec 1.0000 sec

Line, Long, 

Machined
$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Spot Face 0.5000 sec 0.5000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Mill Small Face 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. CDI 1.0000 sec 1.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Mill Small Face 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Chamfer ID 1.0000 sec 1.0000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Unload Part 2.0000 sec 2.0000 sec

Line, Long, 

Machined

$20.81 Operation V Guide, Trans. Load Part 3.0000 sec 3.0000 sec

Line, Long, 

Washed

Design Profit ®

Page 40 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.81 Operation V Guide, Trans. Wash Part Medium 5.0000 sec 5.0000 sec

Line, Long, 

Washed

$20.81 Operation V Guide, Trans. Unload Part 2.0000 sec 2.0000 sec

Line, Long, 

Washed

$44.85 Operation V Trans Pump Clamp Part 3.0000 sec 3.0000 sec

Line Asm, Long

$44.85 Material Mod. V Trans Pump Flare Tube End 1.0000 sec 1.0000 sec

Line Asm, Long

$44.85 Operation V Trans Pump Unclamp Part 1.0000 sec 1.0000 sec

Line Asm, Long

- - - 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 - - -

$20.81 P.-P. Part V Trans Pump V Guide, Trans. Line, Long V Guide, Trans. 2.0000 sec 2.0000 sec

Line Asm, Long Line, Long

$20.81 Tool V Guide, Trans. Washer Turbo Tunnel 0.0000 sec 0.0000 sec

Line, Long

Design Profit ®

Page 41 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$31.33 P.-P. Part V Guide, Trans. V Guide, Trans. Line, Long, V Guide, Trans. 0.0000 sec 0.0000 sec

Line, Long Machined Line, Long, 

Machined

$31.33 Tool V Guide, Trans. EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec

Line, Long, Machine

Machined

$31.33 Part V Guide, Trans. V Guide, Trans. V Guide, Trans. Line, Long, Raw V Guide, Trans. Line, Long, Raw V Guide, Trans. V Guide, Trans. 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec

Line, Long, Material Line, Long, Raw 

Machined Material

- - - Aluminum bar stock 1.0" x 0.5" - - -

- - - 0.1067 lbs. Blank weight - - -

- - - Aluminum $1.10/lbx0.1067= - - -

$0.12

$31.33 Operation V Guide, Trans. Load Part 3.0000 sec 3.0000 sec

Line, Long, 

Machined

- - - Small hole and small spot face - - -

$31.33 Material Mod. V Guide, Trans. Drill Hole 1.0000 sec 1.0000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Spot Face 0.5000 sec 0.5000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

- - - Large Hole and Large Spot face - - -

$31.33 Material Mod. V Guide, Trans. Drill Hole 1.0000 sec 1.0000 sec

Line, Long, 

Machined
$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Spot Face 0.5000 sec 0.5000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

Design Profit ®

Page 42 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$31.33 Material Mod. V Guide, Trans. Mill Small Face 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. CDI 1.0000 sec 1.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Mill Small Face 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Auto Tool Change 5.0000 sec 5.0000 sec

Line, Long, 

Machined

$31.33 Material Mod. V Guide, Trans. Chamfer ID 1.0000 sec 1.0000 sec

Line, Long, 

Machined

$31.33 Operation V Guide, Trans. Unload Part 2.0000 sec 2.0000 sec

Line, Long, 

Machined

$20.81 Operation V Guide, Trans. Load Part 3.0000 sec 3.0000 sec

Line, Long

$20.81 Operation V Guide, Trans. Wash Part Medium 5.0000 sec 5.0000 sec

Line, Long

$20.81 Operation V Guide, Trans. Unload Part 2.0000 sec 2.0000 sec

Line, Long

$44.85 Operation V Trans Pump Clamp Part 3.0000 sec 3.0000 sec

Line Asm, Long

$44.85 Material Mod. V Trans Pump Flare Tube End 1.0000 sec 1.0000 sec

Line Asm, Long

$44.85 Operation V Trans Pump Unclamp Part 1.0000 sec 1.0000 sec

Line Asm, Long

$44.85 Part V Trans Pump V O-ring, Long Tube Asm. V O-ring, Long 4.0000 sec 4.0000 sec

Line Asm, Long Tube Asm.

$44.85 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Line Asm, Long

$44.85 Part V Trans Pump V O-ring, Long Tube Asm. V O-ring, Long 4.0000 sec 4.0000 sec

Line Asm, Long Tube Asm.

$44.85 Operation V Trans Pump Part Manipulation 3.0000 sec 3.0000 sec

Line Asm, Long

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -
Design Profit ®

Page 43 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - 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 - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

Design Profit ®

Page 44 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

- - - Space for Printing - - -

- - - Space for Printing - - -
- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

- - - Space for Printing - - -

$0.00 Part V Transmission V Bolt Trans Pump Lines V Bolt Trans 4.0000 sec 4.0000 sec

Pump Lines

$0.00 Tool V Transmission Power Tool 4.0000 sec 4.0000 sec

$0.00 Fastening V Transmission Power Screw 4.0000 sec 4.0000 sec

$0.00 Operation V Transmission CDI 1.0000 sec 1.0000 sec

$0.00 Multitouch V Transmission Regrab Long trans pump line Regrab Long 6.0000 sec 6.0000 sec

trans pump line

$0.00 Part V Transmission V Bolt, Transmission Pump, Short v Bolt, 7.0000 sec 7.0000 sec

Transmission 

Pump, Short

$0.00 Tool V Transmission Power Tool 4.0000 sec 4.0000 sec

$0.00 Fastening V Transmission Power Screw 4.0000 sec 4.0000 sec

$0.00 Operation V Transmission CDI 1.0000 sec 1.0000 sec

$35.51 Subassembly V Transmission V Trans Pump Line Asm, Short V Trans Pump 8.0000 sec 8.0000 sec

Line Asm, Short

$35.51 Tool V Trans Pump First Fixture 0.0000 sec 0.0000 sec

Line Asm, Short

$35.51 Subassembly V Trans Pump V Trans Pump Line,Short, Asm. V Trans Pump 4.0000 sec 4.0000 sec

Line Asm, Short Line,Short, Asm.

$35.51 Tool V Trans Pump First Fixture 0.0000 sec 0.0000 sec

Line,Short, Asm.

$44.85 P.-P. Part V Trans Pump V Tube, Trans Line, Short V Tube, Trans 6.0000 sec 6.0000 sec

Line,Short, Asm. Line, Short

$44.85 Tool V Tube, Trans Tube Bending Equipment 0.0000 sec 0.0000 sec

Line, Short

$44.85 Part V Tube, Trans V Tube, Trans Line, Short V Tube, Trans 0.0000 sec 0.0000 sec

Line, Short Line, Short, Raw 

Material

- - - Aluminum $1.10/lbx0.0219= Aluminum $1.10/lbx0.0219= - - -

$0.02

Design Profit ®

Page 45 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$44.85 Operation V Tube, Trans Clamp Part 3.0000 sec 3.0000 sec

Line, Short

$44.85 Material Mod. V Tube, Trans Cut to Length 1.0000 sec 1.0000 sec

Line, Short

$44.85 Operation V Tube, Trans Unclamp Part 1.0000 sec 1.0000 sec

Line, Short

$44.85 Operation V Tube, Trans Clamp Part 3.0000 sec 3.0000 sec

Line, Short

$44.85 Material Mod. V Tube, Trans Bend Tube 1.0000 sec 1.0000 sec

Line, Short

$44.85 Operation V Tube, Trans Unclamp Part 1.0000 sec 1.0000 sec

Line, Short
$44.85 Operation V Tube, Trans Part Manipulation 3.0000 sec 3.0000 sec

Line, Short

$44.85 Operation V Tube, Trans Clamp Part 3.0000 sec 3.0000 sec

Line, Short

$44.85 Operation V Tube, Trans Auto Tool Change 5.0000 sec 5.0000 sec

Line, Short

$44.85 Material Mod. V Tube, Trans Flare Tube End 1.0000 sec 1.0000 sec

Line, Short

$44.85 Operation V Tube, Trans Unclamp Part 1.0000 sec 1.0000 sec

Line, Short

- - - 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 - - -

Design Profit ®

Page 46 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$10.75 P.-P. Part V Trans Pump V Support Bar, Tube, Short, V Support Bar, 4.0000 sec 4.0000 sec

Line,Short, Asm. Washed Tube, Short

$10.75 Tool V Support Bar, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec

Tube, Short, DRY

Washed

$31.33 P.-P. Part V Support Bar, V Support Bar, Tube, Short, V Support Bar, 0.0000 sec 0.0000 sec

Tube, Short, Machined Tube, Short, 

Washed Machined

$31.33 Tool V Support Bar, EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec

Tube, Short, Machine

Machined

$31.33 Part V Support Bar, V Support Bar, Tube, Short V Support Bar, 0.0000 sec 0.0000 sec

Tube, Short, Tube, Short, Raw 

Machined Material

- - - Aluminum bar stock 1.0" x 0.308" - - -

- - - 0.0794 lbs. Blank weight - - -

$31.33 Operation V Support Bar, Load Part 3.0000 sec 3.0000 sec

Tube, Short, 

Machined

$31.33 Material Mod. V Support Bar, Drill Hole 1.0000 sec 1.0000 sec

Tube, Short, 

Machined
$31.33 Operation V Support Bar, CDI 1.0000 sec 1.0000 sec

Tube, Short, 

Machined

$31.33 Operation V Support Bar, Auto Tool Change 5.0000 sec 5.0000 sec

Tube, Short, 

Machined

$31.33 Material Mod. V Support Bar, Mill Small Face 5.0000 sec 5.0000 sec

Tube, Short, 

Machined

$31.33 Material Mod. V Support Bar, Mill Small Face 5.0000 sec 5.0000 sec

Tube, Short, 

Machined

$31.33 Operation V Support Bar, Auto Tool Change 5.0000 sec 5.0000 sec

Tube, Short, 

Machined

$31.33 Material Mod. V Support Bar, Chamfer ID 1.0000 sec 1.0000 sec

Tube, Short, 

Machined

Design Profit ®

Page 47 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$31.33 Operation V Support Bar, Unload Part 2.0000 sec 2.0000 sec

Tube, Short, 

Machined

$10.75 Operation V Support Bar, Load Part 3.0000 sec 3.0000 sec

Tube, Short, 

Washed

$10.75 Operation V Support Bar, Wash Part Medium 5.0000 sec 5.0000 sec

Tube, Short, 

Washed

$10.75 Operation V Support Bar, Unload Part 2.0000 sec 2.0000 sec

Tube, Short, 

Washed

$35.51 Operation V Trans Pump Set In Place 1.0000 sec 1.0000 sec

Line,Short, Asm.

$35.51 Part V Trans Pump V Collar, Tube Asm., Short V Collar, Tube 3.0000 sec 3.0000 sec

Line,Short, Asm. Asm., Short

- - - Commodity pricing - - -

$35.51 Operation V Trans Pump Set In Place 1.0000 sec 1.0000 sec

Line,Short, Asm.

$35.51 Part V Trans Pump V Metal Seal, Tube, Short V Metal Seal, 2.0000 sec 2.0000 sec

Line,Short, Asm. Tube, Short

- - - Commodity pricing - - -

$35.51 Operation V Trans Pump Set In Place 1.0000 sec 1.0000 sec

Line,Short, 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 - - -

$10.75 P.-P. Part V Trans Pump V Tube End, Washed V Tube End, 0.0000 sec 0.0000 sec

Line,Short, Asm. Washed

$10.75 Tool V Tube End, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec

Washed DRY

$20.90 P.-P. Part V Tube End, V Tube End, Machined V Tube End, 0.0000 sec 0.0000 sec

Washed Machined

$20.90 Tool V Tube End, CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec

Machined bar

Design Profit ®

Page 48 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$20.90 Part V Tube End, V Tube End, Machined V Tube End, Raw 0.0000 sec 0.0000 sec

Machined Material

- - - Includes Bar Feeder - - -

- - - Bar stock weight 0.1061 lbs. - - -

- - - Box size of finished part D22mm - - -

x L42mm

$20.90 Material Mod. V Tube End, Turn end face 1-30mm 2.0000 sec 2.0000 sec

Machined

$20.90 Operation V Tube End, CDI 1.0000 sec 1.0000 sec

Machined

$20.90 Material Mod. V Tube End, Turn OD 1-30mm 1.0000 sec 1.0000 sec

Machined

$20.90 Operation V Tube End, CDI 1.0000 sec 1.0000 sec

Machined

- - - Cut Majority of Material away Cut Majority of Material away - - -

$20.90 Material Mod. V Tube End, Turn OD 1-30mm 1.0000 sec 1.0000 sec

Machined

$20.90 Operation V Tube End, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$20.90 Material Mod. V Tube End, Cut Groove sml 2.0000 sec 2.0000 sec

Machined

$20.90 Operation V Tube End, CDI 1.0000 sec 1.0000 sec

Machined

$20.90 Operation V Tube End, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$20.90 Material Mod. V Tube End, Chamfer OD sml 1.0000 sec 1.0000 sec

Machined

$20.90 Operation V Tube End, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$20.90 Material Mod. V Tube End, Drill Hole 1.0000 sec 1.0000 sec

Machined

$20.90 Operation V Tube End, Auto Tool Change 5.0000 sec 5.0000 sec

Machined

$20.90 Material Mod. V Tube End, Cut Groove sml 2.0000 sec 2.0000 sec

Machined

$20.90 Material Mod. V Tube End, Cut to Length 1.0000 sec 1.0000 sec

Machined

$10.75 Operation V Tube End, Load Part 3.0000 sec 3.0000 sec

Washed

$10.75 Operation V Tube End, Wash Part Medium 5.0000 sec 5.0000 sec
Washed

Design Profit ®

Page 49 of #

Copyright 2005© Munro & Associates, Inc.

V Transmission

Labor Type Parent Name Symbol Name Number Munro Actual Time

Rate Score

$10.75 Operation V Tube End, Unload Part 2.0000 sec 2.0000 sec

Washed

$35.51 Tool V Trans Pump Soldering Fixture 2.0000 sec 2.0000 sec

Line,Short, Asm.

$35.51 Fastening V Trans Pump Solder Leads 5.0000 sec 5.0000 sec

Line,Short, Asm.

$35.51 Part V Trans Pump V Foam Seal, Trans Pump Line V Foam Seal, 4.0000 sec 4.0000 sec

Line Asm, Short Trans Pump Line

- - - Assumed to be cut from large roll - - -

$35.51 Fastening V Trans Pump Push In Place 2.0000 sec 2.0000 sec

Line Asm, Short

$35.51 Part V Trans Pump V O-ring, Trans Pump Line V O-ring, Trans 6.0000 sec 6.0000 sec

Line Asm, Short Pump Line

$35.51 Tool V Trans Pump Hand Tool 3.0000 sec 3.0000 sec

Line Asm, Short

$35.51 Operation V Trans Pump Set O-ring in Place 2.0000 sec 2.0000 sec

Line Asm, Short

$0.00 Part V Transmission V Bolt Trans Pump Lines V Bolt Trans 6.0000 sec 6.0000 sec

Pump Lines

$0.00 Tool V Transmission Power Tool 4.0000 sec 4.0000 sec

$0.00 Fastening V Transmission Power Screw 4.0000 sec 4.0000 sec

$0.00 Multitouch V Transmission Regrab Trans Pump Line, Short, Regrab Trans 6.0000 sec 6.0000 sec

Start Fitting Pump Line, 

Short, Start 

Fitting

$0.00 Tool V Transmission Hand Tool 3.0000 sec 3.0000 sec

$0.00 Fastening V Transmission Manual Screw 7.0000 sec 7.0000 sec

Report Totals Count: ##

Design Profit ®

Page 50 of #

Copyright 2005© Munro & Associates, Inc.
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.04 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.08 1 -

$0.00 $0.00 1 $0.00

$1.17 $0.51 1 $1.17

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.04 1 $0.00

$0.00 $0.02 1 $0.00
- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 4 $0.00

$0.00 $0.01 3 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.02 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.02 2 $0.00
$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 4 $0.00

$0.00 $0.01 3 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.00 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -
- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

$0.15 $0.04 1 $0.15

$0.00 $0.06 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.03 1 $0.00

- $0.05 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

$0.18 $0.00 1 $0.18
- - - -

$0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.13 1 $0.00

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.13 1 $0.00

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.13 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- $0.09 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.00 1 $0.00

$0.12 $0.00 1 $0.12

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.05 1 $0.00

$0.00 $0.10 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.10 1 $0.00

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- $0.02 1 -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.00 1 $0.00
- $0.00 1 -

$0.00 $0.00 1 $0.00

- - - -

$0.04 $0.00 1 $0.04

- - - -

- - - -

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.02 1 $0.00
$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.03 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.08 $0.08 1 $0.08

- $0.07 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.08 1 -

$0.00 $0.00 1 $0.00

$0.39 $0.12 1 $0.39
- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.03 1 $0.00

$0.00 $0.01 5 $0.00

$0.00 $0.01 4 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.02 $0.02 4 $0.06

$0.00 $0.06 1 $0.00
$0.00 $0.04 1 $0.00

$0.00 $0.03 1 $0.00

- - - -

- - - -

- $0.06 1 -

$0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.07 $0.00 1 $0.07

- - - -

- - - -

- - - -

- - - -

$0.10 $0.03 1 $0.10

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.09 1 -

$0.00 $0.00 1 $0.00

- $0.05 1 -
$0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- $0.02 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.08 1 -

$0.00 $0.00 1 $0.00

$0.32 $0.13 1 $0.32

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.03 2 $0.00

$0.00 $0.01 1 $0.00
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.03 1 $0.00

$0.00 $0.03 2 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 2 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 2 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.03 1 $0.00
$0.00 $0.01 2 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 2 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 2 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.02 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- $0.03 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -
$0.00 $0.00 1 $0.00

$0.03 $0.00 1 $0.03

- - - -

- - - -

- - - -

- - - -

$0.50 $0.05 1 $0.50

$0.50 $0.05 1 $0.50

$0.00 $0.02 2 $0.00

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- $0.02 1 -

$0.00 $0.00 1 $0.00

$0.01 $0.04 1 $0.01

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

$0.00 $0.03 1 $0.00
$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

- - - -

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.02 1 -

$0.00 $0.00 1 $0.00

$0.01 $0.00 1 $0.01

- - - -

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00
- - - -

$0.00 $0.02 2 $0.00

$0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- $0.05 1 -

$0.00 $0.00 1 $0.00

$0.01 $0.00 1 $0.01

- - - -

- - - -

- - - -

- - - -

$0.00 $0.05 2 $0.00

$0.00 $0.02 2 $0.00

- - - -

- - - -

- - - -

- $0.05 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

$0.00 $0.00 1 $0.00

$0.07 $0.01 1 $0.07

$0.10 $0.01 1 $0.10

- - - -

- - - -

- - - -
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- $0.04 1 -

$0.00 $0.00 1 $0.00

$0.04 $0.05 1 $0.04

- - - -

$0.01 $0.02 1 $0.01

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.02 $0.04 1 $0.02

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

- $0.04 1 -

$0.00 $0.00 1 $0.00

- - - -

$0.04 $0.05 1 $0.04

- - - -

$0.01 $0.02 1 $0.01

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)
- - - -

$0.02 $0.04 1 $0.02

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.02 $0.02 2 $0.04

$0.00 $0.03 1 $0.00

$0.00 $0.03 2 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -
- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.03 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

$0.00 $0.00 1 $0.00

- - - -

- - - -

- $0.03 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

$0.13 $0.00 1 $0.13

- - - -

- - - -

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00
$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.02 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -
- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.02 1 -

$0.00 $0.00 1 $0.00

- - - -

- $0.02 26 -

$0.00 $0.00 26 $0.00

$0.03 $0.00 26 $0.78

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

$0.00 $0.00 1 $0.00
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

- - - -

- $0.04 1 -

$0.00 $0.00 1 $0.00

- $0.00 12 -

$0.00 $0.00 12 $0.00

$0.01 $0.00 12 $0.14

- - - -

- - - -

- - - -

- - - -

$0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.00 12 $0.00

$0.14 $0.13 1 $0.14
- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.05 1 $0.00

$0.00 $0.05 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.92 1 $0.00

$0.00 $0.03 1 $0.00

- - - -

- - - -

$0.00 $0.00 1 $0.00

$0.00 $0.02 1 $0.00

$0.19 $0.06 2 $0.39

$0.00 $0.25 2 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 12 $0.00

$0.00 $0.01 11 $0.00

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.25 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.02 1 $0.00

- - - -

$0.00 $0.08 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.02 4 $0.00

$0.00 $0.01 3 $0.00

- - - -

$0.00 $0.08 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.24 $0.05 1 $0.24
- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

$0.33 $0.03 1 $0.33

$0.00 $0.02 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.05 1 -

$0.00 $0.00 1 $0.00
$0.07 $0.00 1 $0.07

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.02 1 $0.00

- $0.05 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

$0.00 $0.00 1 $0.00

$1.17 $0.02 1 $1.17

- - - -

- - - -

- - - -

- - - -

- - - -

$1.63 $0.03 2 $3.26

- - - -

$0.00 $0.01 2 $0.00

$0.05 $0.01 2 $0.10

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

$0.02 $0.02 1 $0.02
$0.00 $0.01 1 $0.00

$0.02 $0.02 2 $0.03

$0.00 $0.03 1 $0.00

$0.00 $0.03 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.04 $0.02 2 $0.07

$0.00 $0.06 1 $0.00

$0.00 $0.04 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -
- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.07 1 -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.00 1 $0.00

$0.18 $0.02 1 $0.18

$0.00 $0.06 1 $0.00

$0.02 $0.06 1 $0.02

$0.00 $0.03 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.06 1 $0.00
$0.02 $0.08 1 $0.02

$0.00 $0.03 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

- $0.10 1 -

$0.00 $0.00 1 $0.00

- $0.02 1 -

$0.00 $0.00 1 $0.00

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.05 1 $0.00

- $0.03 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

$0.09 $0.00 1 $0.09

- - - -

- - - -

- - - -

- - - -

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00
$0.00 $0.03 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.02 1 $0.00

- $0.04 1 -

$0.00 $0.00 1 $0.00

$0.15 $0.04 1 $0.15

$0.07 $0.03 1 $0.07

$0.00 $0.03 1 $0.00

$0.00 $0.02 1 $0.00
$0.00 $0.02 1 $0.00

$0.00 $0.06 1 $0.00

$0.00 $0.03 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.05 $0.00 4 $0.21

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

- - - -

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.04 1 -

$0.00 $0.04 1 $0.00

- $0.07 1 -

$0.00 $0.00 1 $0.00

$0.20 $0.07 1 $0.20

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 8 $0.00

$0.00 $0.01 8 $0.00

$0.00 $0.04 8 $0.00

$0.00 $0.04 8 $0.00
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.07 1 -

$0.00 $0.00 1 $0.00

$0.14 $0.00 1 $0.14

- - - -

- - - -

- - - -

$0.00 $0.04 1 $0.00

$0.00 $0.04 2 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -
- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.04 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

$0.12 $0.00 1 $0.12

- - - -

- - - -

- - - -

$0.00 $0.03 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.04 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.04 1 $0.00

- - - -

$0.00 $0.01 1 $0.00
$0.00 $0.04 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -
- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- $0.02 1 -

$0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- $0.00 1 -

$0.00 $0.00 1 $0.00

$0.12 $0.00 1 $0.12

- - - -

- - - -

- - - -

$0.00 $0.03 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.04 1 $0.00

- - - -

$0.00 $0.01 1 $0.00
$0.00 $0.04 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.08 $0.05 1 $0.08

$0.00 $0.04 1 $0.00

$0.08 $0.05 1 $0.08

$0.00 $0.04 1 $0.00

- - - -

- - - -

- - - -
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- - - -

- - - -
- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

$0.05 $0.00 1 $0.05

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.02 $0.00 1 $0.02

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.04 1 -

$0.00 $0.00 1 $0.00

- $0.06 1 -

$0.00 $0.00 1 $0.00

$0.02 $0.00 1 $0.02

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 3 $0.00

$0.00 $0.01 3 $0.00
$0.00 $0.04 3 $0.00

$0.00 $0.04 3 $0.00

$0.00 $0.06 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

- $0.04 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

$0.09 $0.00 1 $0.09

- - - -

- - - -

$0.00 $0.03 1 $0.00

$0.00 $0.01 2 $0.00
$0.00 $0.01 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.04 1 $0.00

$0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.02 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.02 $0.03 1 $0.02

- - - -

$0.00 $0.01 1 $0.00

$0.01 $0.02 1 $0.01

- - - -

$0.00 $0.01 1 $0.00

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -
- - - -

- - - -

- $0.00 1 -

$0.00 $0.00 1 $0.00

- $0.00 1 -

$0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.10 $0.00 1 $0.10

- - - -

- - - -

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

- - - -

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 2 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.03 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00

$0.00 $0.01 1 $0.00
Actual Time Piece Cost Total Labor Qty Piece Cost 

Cost (Total) (Total)

$0.00 $0.01 1 $0.00

$0.00 $0.02 1 $0.00

$0.00 $0.05 1 $0.00

$0.01 $0.04 1 $0.01

- - - -

$0.00 $0.02 1 $0.00

$0.06 $0.06 2 $0.11

$0.00 $0.03 1 $0.00

$0.00 $0.02 2 $0.00

$0.05 $0.00 1 $0.05

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

$0.00 $0.00 1 $0.00

834 $12.91
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

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

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

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

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.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:8/21/2012

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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly. 9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.00

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

Mark-up $0.00

T1 or OEM Total Manufacturing Cost: $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Supplier for Subassembly.

3

1

Notes: 

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 #N/A #N/A #N/A #N/A #N/A #N/A $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: #N/A

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810e7549.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:8/21/2012

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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

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

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

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

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

$0.00

2

Notes: 

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

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.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:8/21/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.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:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411